WARNING: If you have an ABS equipped bike, read this!

thanks

:thumb Thanks Joker, mine was routed the same, no excuse as i was the one taking the wheel off, just in time though hadnt worn through.
 
Finally a reply...

Hi guys,

Sorry for the delayed reply - weekend and all. Anyway, thanks for allt he well wishes, I'm fine. I guess that riding crappy mopeds and all other sorts of contraptions in my younger years paid off and somehow got me instinctively to avoid the cars.

Having read that Tobers and snave1 has had their cables routed the wrong way, I'm happy with the results so far. :)

One by one... :)

Cestria said:
Must have been a brown adrenalin moment that one!
Pleased you are OK. Thanks for the heads up.

Indeed it was - All fine now tho :thumb



Gauloises said:
Glad your ok Joker,
But the Incompetence shown by that garage is unbelievable,
to let you ride away with a lead rubbing against the disc is down right
dangerous...

Name and shame

I've been to the garage - I've handed over a printout of the PDF and they all came to have a good look at it - I don't think they'll let this happen again; which is all that I want out of this. I also reckon that they're a good bunch of people, and I see no need for us to stir the pot anymore. I can, after assuring you here on the forum (via this post) and showing them their errors, recommend their services.


Kropotkin said:
I'm going to post this in the Dutch GS Forum, if you don't mind. I'll host the file on my website. If you have any objections, PM me and I'll take it down, but from the gist of your post, I'm guessing you won't mind.

PDF here : http://www.xs4all.nl/~daisy/GS/1200...nsor-wiring.pdf

One question though: After your first brush with brakelessness, did you consider turning the ABS off, to see whether it would still work?


Kropotkin, of course, feel free to post the PDF anywhere (just don't sue me :P). Let's hope it prevents this problem occurring for someone else. :) Please keep me posted if this is something that's happened in the Netherlands too.

When I checked the bike, I didn't really know what to look for. Usually on a traditional bike you look for leaks, oil, fluids, bent-broken stuff, loose-stuff, etc. Checking an electrical cable didn't really occur to me in the haze. In hindsight I should probably have turned ABS off then and there - but then again, it didn't report any errors...


Emoto said:
--snip--
From a software development point of view, this incident is a failure mode that BMW did not write code to handle immediately. I think that writing a letter to BMW detailing the shortcomings of the error handling might have some benefit.
--snip--

Pukmeister said:
I think BWM should definitely be told about this one. They may know about it already, but if told they may be able to rectify it with an easy recall notice to fit new wiring clips or something.

Yup! :) A letter to BMW is planned, at some point.


rc46 said:
My point is that you have to trust anyone who works on your bike with you life. I prefer to work on my bike myself. I am also in the camp that feels the upside of the ABS system far out weighs any downsides. I have been saved a by it a few times myself.

You're right - you do trust them with your life. And what's even worse, you can't sue before something bad has happened (even if sueing wouldn't be the optimal thing to do). I also prefer to look after my own machines; but as this bike is so new, I'll stick with someone else doing it. And besides, I don't have tyre-changing eqipment (yet??).


johnnybravo said:
Just as a matter of interest, you say you're near Oxford, whereabouts? It wasn't you I saw going through Middle Barton yesterday evening was it?

Nope wasn't me - however, Middle Barton isn't too far off my paths... :)


nemezis said:
There has been a recently a recall for the BMW K1200S for rerouting this cable. First information was on 06/13/2005 an can be found here:

http://www.michaelbense.de/k1200s/f...6aac5248ac7ef92

Scroll down for the picture, you see the fix done by BMW for the K1200S. It seems to me that this issue is well known.

Thanks for the link - I had a quick look, and I think that clips like that would have kept my sensor cable from getting "lost" - it doesn't require much. :)



pogo said:
I had a close look to my own bike,and to my opinion ,once again,BMW are not to blame.dont need to be a engeneer to see which way the wire has to take to be at the right place.It is obvious,and this cable dont need more protection or bigger size if the job is done the right way.Like on airplanes,or anywhere the security purpose is involved,a special attention must be payed when doing maintenance.Your mechanic made a BIG mistake,not taking care enought on that particulary spot.I cant figure what would happen if that failure would happen in other circonstances....anyway,congratulations for your good management of the situation

birdseye said:
Thanks for the warning but I really dont see this as a BMW fault. The tyre fitters were negligent in not refitting the wheel properly. Just as much as if they hadnt tightened up the wheel nuts - and you wouldnt have blamed BMW for not having self tightening nuts, would you?

Trouble is, the fitters have cocked up but will anything happen to them as a result? Probably not, so they will go on cocking up. Why should they care?


As I said in my initial post that for this to occur two things need to happen a) it needs to be possible "misplace" the cable b) someone needs to do it. I'm not blaming BWM per se, in fact, I'm looking for somenoe to blame at all. What I wish to do is to prevent this from happening again. This thread hopefully will prevent more cables being incorrectly routed. As stated above, I've spoken to the garage and shown them their errors, so hopefully that should sort them out. If they don't do it properly next time it's time to name n shame.
With regards to BWM's part in this. It's my belief that certain parts are designed to prevent errors happening (a bike engine, in most cases, is designed to sit in the frame so that it can't fall out of it). Or you have an excessive safety margins (handlebars fastened with 4 bolts). I think that brakes should have both the preventive design and the excessive safety margins.
Personally I would like to see one or more of the following features:
- Two separate sensors - if they don't read exactly the same, there's a problem (this is probably too expensive)
- Shielded cable. A cable that has got a thin wire running up and down and all around the length of the whole cable, and a small current running through this and if the wire is broken somewhere it's a sign that the cable is damaged or is about to be damaged.
- Metal/plastic/some shielding of the cable that would a) prevent damages to it and b) possibly fix it to a certain form, so that it can't be routed incorrectly.
- CLIPS (as on the K1200S) where the cable is held securely.

I think BMW's "fault" in this issue is that such an important thing is allowed to be routed incorrectly.


snave1 said:
:thumb Thanks Joker, mine was routed the same, no excuse as i was the one taking the wheel off, just in time though hadnt worn through.

Blimey! I'm so glad nothing more happened! To me having 3 bikes with this "problem" is kind of proof enough that this is an issue that needs to be highlighted.


Thanks again for all your kind words! :)

It's a lovely bike and I'm taking mine to the 'Ring again this w/e (where I ride with ABS off btw ;) )

:thumb :beer:
 
I checked mine (Nov 04) and it looks like the cable is fitted wrongly, in that it goes in front of the caliper. However, there is a small d-clip fitted to back of the fork leg about half way between the caliper mounts and if I try to relocate the cable as suggested it would put a tight bend in it. So, is the clip a new modification to address the problem or should I still force (gently of course) the cable into the recommended position?
 
Jim Ross said:
I checked mine (Nov 04) and it looks like the cable is fitted wrongly, in that it goes in front of the caliper. However, there is a small d-clip fitted to back of the fork leg about half way between the caliper mounts and if I try to relocate the cable as suggested it would put a tight bend in it. So, is the clip a new modification to address the problem or should I still force (gently of course) the cable into the recommended position?

Ask your dealer - you don't want to take any chances fiddling with your brakes. :thumb
 
TheJoker said:
Ask your dealer - you don't want to take any chances fiddling with your brakes. :thumb

Fair comment, but out of interest did yours have the d-clip or is this a later modification?
 
Jim Ross said:
Fair comment, but out of interest did yours have the d-clip or is this a later modification?

As far as I've seen, I have no clips - just cable ties around my brake-hose. Don't take my word for it tho - there might be something that I've missed.

Using common sense, I guess you're OK as long as the cable doesn't get damaged.
 
I think if it just relies on being in front of the caliper bolt to stop it going on disc then bmw should do something about it, i have no D clips on mine to secure it. But cant blame anybody but myself in this instance. :(
 
Mine is routed correctly, and has d clips. The dealer also added a tie-wrap after rotor swap under waranty.
 
drdata said:
Mine is routed correctly, and has d clips. The dealer also added a tie-wrap after rotor swap under waranty.

Thanks for letting us know - any chance of some pictures?
 
Is this what you mean?

As supplied from new (March 05)
 

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Outtomunch said:
Is this what you mean?

As supplied from new (March 05)


Yes, and sorry for lack of visual aids. Have to tool on over to work so no camera time.

Cheers
 
Thanks Joker! Your PDF-attachment stored on my computer. Glad you made it trough!
 
Outtomunch said:
Is this what you mean?

As supplied from new (March 05)

Oh, those :) Yah, I've got exactly the same.
attachment.php

But as you can see on this pic, if the cable is routed on the other side of the calliper, the clip (and the cable-tie) won't do much good as the distance is shorter to the sensor, thus creating a kink in the cable - a kink that's just nicely kinky enough (ooeeerrr) to touch the disk - in my case at least...

Thanks for the pics! :beer:
 
but be carefull those clips or cable tie wouldnt stop you putting cable wrong side of caliper bolt and allowing it to touch rotor.
 
snave1 said:
but be carefull those clips or cable tie wouldnt stop you putting cable wrong side of caliper bolt and allowing it to touch rotor.

Wow. I just re-checked and sure enough, depite having the cable wraps and ties, the cable is routed on the wrong side of the caliper. After a bit of wiggling I found I can touch the disk with the cable:

abs_cable.jpg




abs_cable2.jpg
 
I don't think this highlights any fundumental flaw in BMWs ABS system. Any ABS system could react this way. I had a somewhat similar problem, but it was on my Toyota Landcruiser.

My right front wheel would sometimes go into "ABS" mode while coming to a stop on dry pavement. The ABS system would only sometimes recognize this as an error and switch to normal non-ABS mode.

It was a little un-nerving, but since it only happened a very slow speeds , less than 5 mph, it was easy to control the pull to the left.

That is until the last time it happened. I was going 50 mph, used the brakes and almost crashed into the guy in the next lane!!

The problem with my ABS? A bad wiring harness that connects both front wheel sensors. Visually it looked fine.
 
In SPC this morning I noticed BWM had added an extra clip on the latest bikes, also a different side stand mount, and different rear shock, might be old news but there you go :nenau

Shep
 
In view of the importance of this subject and the fact that the problem has occurred again recently I have 'stickied' this thread. :thumb
 
My R1200GS was delivered this morning from the dealer, with the cable in the wrong place. It's an 04 bike. The sales person who delivered it did not appear to be aware of this problem.

The cable can definitely touch the brake disc. Instructions on how to move it would be appreciated ;)

Trip
 


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