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Discussion Starter #1 (Edited)
I have a R1200GS 2006 Model.

I have been having problems with ABS and brake failure staying on / flashing. After many hours of research the problem was the elect assist servo module with ABS. Because of the cost this is how to remove the module pump, re-plumb brake pipes and split the pump keeping the module intact to ensure brake switches and speedo still work.

1. Connect pipe from front master cylinder to front callipers. Use existing 4 way union, but use one side of the union.

2. Use existing pipe from union on rear frame. Cut, flare and fit new male brake pipe end into rear master cylinder.

3. Remove tank

4. Remove Servo pump complete.

5. Split pump and remove electrical pump connections from the hydraulic pump side. Reconnect multi plug and refit the module only using existing rubber mounting (i fitted a small cover over module and sealed to keep water out.

6. Bleed Brakes as normal and refit tank.

7. You now have it great brakes with no servo. Saving £1000 and it works !!!!.:)

8. I am working on extinguishing the flashing brake failure and warning light. I am thinking if splitting the dash and just removing the LED's. This is cheapest option.
 

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2006 Brakes

Thanks for doing the research and writing up the way to do this, if one wishes to avoid the high cost of repair!! It may be an option for me, should this ever happen. How many miles did you have on the bike when this happened? Do you change the brake fluids, or can you attribute the failure to any particular reason?
Sorry for the brake failure!!
Thanks.
 

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Discussion Starter #3 (Edited)
Removing ABS Pump

After removing the ABS pump and doing the brake pipe mod the brakes can bleed as normal. This mod will save you a 2.5 K bill from BMW. It all works as I have done it and the brakes are better. You can do a hill start without having to stand heavily on the rear brake pedal.

Hope this helps!!!

PS The problem happened at 36,000 mls
The Complex elect assist servo with ABS is over engineered and too complex for the job it is desigined to do. This problem is really common and BMW won't help unless you pay the massive bill. They won't talk to you about any MOD to the origional build standard.
 

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servo removal

Just done all of the above but speedo will not work!
Have I missed something!
Brake hydraulics were a doddle but speedo will not work after following all the info'.
HELP! MOT date is rapidly approaching.
I am new to this site and any help will be greatly appreciated.

thanks willwatt10
 

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Abs removal

Excellent description, i am in the same boat. My concern was getting throught the MOT with warning lights - any thoughts ?
 

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OK...one reference to MOT I could ignore but that's two of you. Maybe if we filled out our bio's before posting it might give a clue, but no one seems to do that anymore:) Anyway, MOT, is that some kind of annual inspection you guys are worried about? Just a wild guess:confused:
 

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I'm in the UK, and correct the MOT is an annual inspection to check for road worthiness - Ministry of Transport.

Recent changes mean that no warning lights/indicators are allowed - ABS systems, Airbag warnings etc. The next threat on the horizon is European wide legislation - could come down to no modifications allowed.

There are differences between bikes and cars. Bikes may have ABS removed, cars can't - don't know the reason behind that. So as far as this mod is concerned, I may get away with it this year but if rules are tightened what holds for future tests, I may be left with a bike I can't sell or ride legally.
 

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servo removal

sorry for the long delay, thru work and a noggy internet server.
this is the full story on my problems with the servo - abs system on my 2004
gs. speedo failed, abs lites flashing and servo running while ignition on. brakes still worked as normal !!! tried a new rear wheel speedo sensor no luck.
decided to bin the whole sh*tty system. when i pulled the electrical plug on the pump i still had working brake lites. i tried james mcewan's remedy but still no working speedo. hydraulic brake system was easily fixed with self build brake lines. lites on dash very easily fixed by removing and splitting dash and blocking the small chambers where the led,s live. i bought a gps operated speedo from digital speedos and mounted this on a plate just above the original speedo.
this sits flush with the rest of the dash and looks just fine.
bike is now thru mot and the brakes are first class.
only drawback i have found is that the indicators do not self cancel themselves when in motion.
hope this helps any guys in a similar situation
 

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Discussion Starter #11 (Edited)
Elect ABS Servo MOD

After the mod my speedo worked. You have to split the ABS Pump from the Module. The wires have to be carefully removed insulated and tucked unside the module. I manafactured a backing plate and sealed it with RTV. The module only has to be refitted using its origional mountings. The multi plug has to be reconnected. After that the speedo should work. The flashing lights is an easy fix. Split the clocks and insert small bits of black foam rubber in the small compartments covering the flashing lights and fit clocks back together.

My brakes are miles better.
 

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abs brake failure

I had the brake failure light on and the fault was in the motor.
I stripped the motor and repaired the common sticking brush and it works a treat.
I have since done more than 10 successful repairs on these motors.
 

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I have a R1200GS 2006 Model.

I have been having problems with ABS and brake failure staying on / flashing. After many hours of research the problem was the elect assist servo module with ABS. Because of the cost this is how to remove the module pump, re-plumb brake pipes and split the pump keeping the module intact to ensure brake switches and speedo still work.

1. Connect pipe from front master cylinder to front callipers. Use existing 4 way union, but use one side of the union.

2. Use existing pipe from union on rear frame. Cut, flare and fit new male brake pipe end into rear master cylinder.

3. Remove tank

4. Remove Servo pump complete.

5. Split pump and remove electrical pump connections from the hydraulic pump side. Reconnect multi plug and refit the module only using existing rubber mounting (i fitted a small cover over module and sealed to keep water out.

6. Bleed Brakes as normal and refit tank.

7. You now have it great brakes with no servo. Saving £1000 and it works !!!!.:)

8. I am working on extinguishing the flashing brake failure and warning light. I am thinking if splitting the dash and just removing the LED's. This is cheapest option.
YEP this option is definitely the way to go.
I have had no end of problems with the Servo Brake system culminating in total failure in the Snowy Mountains. ( with wife on the back ! )
BMW quoted $4000+ to install new unit.
I have removed the entire system from my 2005 GS which involved splitting the Hydraulics unit from the ABS ECU. You need to do this to retain the speedometer and indicator self cancel functionality.
The brake lines need replumbing which is relatively simple.The brakes work like a conventional system with no side effects.
There are warning lights on for brake failure which require the bulbs to be removed.
This is my sixth Beemer and by far the worst in terms of reliability and repairs, including a broken shaft unit.
I hope the new ones are better otherwise we may look at a Multistrada next.
 

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Speedo after servo removal

Not sure if anyone still active on this thread as dated 2013 but ...
I have just removed the servo system and left the ABS module connected and now have no speedo! I'm wondering if anyone found out why it works for some and not others. Wondering if it needs earthing on the chassis as I sealed mine in a plastic box. I'm sure when I drove round the yard with everything hanging loose and no bodywork it worked but maybe I was dreaming. It's a 2004 model.
 

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I have the same problem. After removing the servo unit and retaining the electronics I have no speedo. My brake lights worked even without the abs electronics. Anybody have any answers?
Does the rear wheel signal go through the ECU and then the ABS before going to the speedo and does the ABS disconnect the signal when a fault is detected or does the rear wheel signal go direct to the ABS for processing before going to the speedo?
Anybody know of a decent wiring diagram to check this out?
 

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Anyone have photos of how they 'split' this abs unit as far as i see it in 4 separate parts just what do we split and what internal wiring is disconnected or altered.

I have a 05 1200GS i got on the cheap from the local BMW dealer that didn't want to get involved or spend any money on and it came as is where is with the abs problem.

ok i found and saved this if it helps anyone.

http://advrider.com/index.php?threads/2005-1200gs-abs-delete-help-needed.991572/]2005 1200GS ABS delete help needed | Adventure Rider
 

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'05 R 1200 Gs
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Anyone have photos of how they 'split' this abs unit as far as i see it in 4 separate parts just what do we split and what internal wiring is disconnected or altered.

I have a 05 1200GS i got on the cheap from the local BMW dealer that didn't want to get involved or spend any money on and it came as is where is with the abs problem.

ok i found and saved this if it helps anyone.

http://advrider.com/index.php?threads/2005-1200gs-abs-delete-help-needed.991572/]2005 1200GS ABS delete help needed | Adventure Rider
That link is not working as pasted. .
 

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That worked. Thank you.
I'm adding to this very late in the day. But just in case there are others out there looking at this thread and trying to figure things out, I can add this. I did this modification to my 2005 R1200GS but found that the speedo didn't work. I wasn't keen on the idea of a GPS speedo, so I bolted the circuit board section back on to the ABS unit, connecting up the ribbon connectors and the two connectors on the top of the ABS unit itself, but not connecting the power leads to the two servo pumps. Bingo. The speedo works fine now.
 
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