Brake Failure Warning 2005 R1200GS

[Zag999]

Hi all, after a bit of advice. I flushed my brake fluid on a 2005 GS with servo brakes. Job went well apart from now, after about 20 min of riding the warning triangle comes on and Brake Failure light flashes fast. Brakes feel fine though. If I switch off and restart, warning goes away for 20 min then comes back. I know the servos are sensitive to contamination so I properly cleaned the abs unit before removing reservoir plugs and opening bleed nipples.

I used an ABS reservoir filler which I bought from MOTORWORKS to flush the secondary circuit. With ignition on, hold brake lever or pedal lightly while bleeding at the caliper to let the servo push fresh fluid through.

Brakes feel great after, just keep getting this warning.

Any ideas welcome!

 

[botus]

the early ones (pre a 2006 / 2007 model year update that got a later better ABS2 system) have an ABS system that is a failure waiting to happen - I believe once it dies no one is able to repair - not sure if you won the lottery, if you can even buy the part now...

as your issue comes straight after work it must a be a remote possibility there is something to be finished, but its 99% likely it died due to the exercise it just got

I'll let others state more suggestions, but likely its had it - and you need to look at ideas on discarding the system as the majority of owners do - just yesterday one of the indy techs out there on this forum posted this picture of the ones he's sorted out

 

[Zag999]

Thanks for your reply Botus. I was worried I might have introduced some contamination or shifted something already there into blocking something. Just wondered if anyone else knew what the symptoms might be if the brakes actually being ok but the fault being present.

I might ask a local group if they know anyone who could diagnose the fault before I scrap the ABS unit.


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[Magwych]

IIRC, a failed brake light bulb will throw this error too.
The rear lights on the servo era bikes are old school filament bulbs. When the central ECU detects a bulb has gone, it throws an error then uses an increased voltage on the rear tail light when braking.
It may becwirthwhile checking the bulbs, before consigning the brake system to the bin, just in case

 

[Smiffypr]

I can't think of anything that would take 20 minutes to show up. I think your best bet is to read the fault codes. In the mean time, make sure that the brakes still do work with the ignition off, because if there is something electrical failing after 20 minutes of being powered, it may well lead to the Servo being shut down after a longer period. (Yes it is possible for the servo brakes to work perfectly but for the brakes not to work at all without the servos running).

 

[Zag999]

Thanks Smiffypr. Currently at the IoM TT it failed on way. Borrowed a mates bike to get me here. So I’ll sort it next weekend when back and try what you suggested.


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[Steptoe]

There are lots of potential causes to make the warning light(s) come on. Some major, some very minor. The only way to find out exactly is to have the code’s read, otherwise any suggestions are pure guesswork.

 

[Jamesoid]

A couple of weeks ago, I replaced the ABS servo unit on my 2005 with a Motorworks ABS delete kit.
Linky

It was a bit pricy, but meant I didn't have to muck about with sourcing other hoses and mounting the electronic unit. Cracking the speedo housing to black out the ABS warning light was also pretty straightforward. There are instructions for this all somewhere on this website...which is what I followed (I think).

After a good bleed (the brakes, not me) everything is working fine.

 

[Zag999]

Hey Jamesoid

Sounds like you got that sorted then.

I was waiting for a few months before updating this thread, to prove the fix.

I purchased the GS-911 software to read the code, as it would also be useful for future.

I carried out the Brake Bleed Test procedure on front and back, which consisted of pulling the lever hard enough to achieve a certain pressure in the secondary circuit. No tools required. In this mode, just with ignition on, the ecu didn’t operate the servo motor. It passed the tests.

So I’ve done nothing mechanical to it, I just did the brake bleed test and cleared the fault. The fault hasn’t come back since and I’ve done about 1000 miles. So I’m happy that it’s sorted.

Well worth the £300 for the GS-911!

Thanks for all your comments.


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