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"K12S/KR" Technical Q&A K1200S/R Technical Questions/Answers

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  #1  
Old 04-18-2017, 12:50 AM
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Servo Assisted ABS Removal - I-ABS Install

I am removing my 05-06 Servo Assisted ABS and install the new gen. I-ABS.

First off, I have had no problem with the Servo Assisted braking, and my pump unit has not failed (yet).

But because parts are cheap, if you look in the right places, and knowing some of the electrics on the bike i decided to remove the old system and upgrade.
And I can sell the pump module by itself and get my money back.....

(More) Pictures and write ups will follow when going deeper into the project.
Attached Images
File Type: jpg Wiring harness.jpg (319.6 KB, 63 views)
File Type: jpg Wiring harness Instrument.jpg (162.8 KB, 45 views)
File Type: jpg Wiring harness Key.jpg (105.5 KB, 47 views)
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Old 04-18-2017, 02:20 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

I bought a second hand wiring harness from a 07 K1200s for the install.....

The computer is hooked up and I am updating the VIN number from the I-ABS module to the Bike using WinkFP.
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File Type: jpg VIN number update.jpg (49.9 KB, 43 views)
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Old 04-18-2017, 04:05 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Your just to clever Patrique
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Old 04-18-2017, 04:11 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Patrique, you should start a mobile BMW mechanics business and travel around Australia servicing and repairing them.
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Old 04-18-2017, 05:12 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

I know..... business would be great.
But i don't wan't your local BMW stealership to go broke by fixing shit only once.

Because they support the local community by providing valueable services to the public and paying their "BMW Trained Technicians" minimum wage.

I'd endup taking away the miserable livelyhood of a poor mechanic.......

Just kidding..... I'll take cash payments and free accomodation anytime!!!!
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Old 04-18-2017, 07:16 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Quote:
Originally Posted by Patrique83
I know..... business would be great.
But i don't wan't your local BMW stealership to go broke by fixing shit only once.

Because they support the local community by providing valueable services to the public and paying their "BMW Trained Technicians" minimum wage.

I'd endup taking away the miserable livelyhood of a poor mechanic.......

Just kidding..... I'll take cash payments and free accomodation anytime!!!!

You might be surprised how many takers you get. Will you work for beer and accommodation?
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Old 04-18-2017, 08:15 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

What kind of a business plan would that be?

Driving around Australia in a white van and get drunk for free........

But you are welcome to drop by anytime in Camden, for a free consultation
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Old 04-18-2017, 11:47 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Late night garage session.....

I removed my 05 ZFE, BMSK and Instrument Cluster and connected it to the 2007 wiring harness (I-ABS 2 was already plugged in).

Checked that all components are talking to each other using INPA and recoded the Instrument Cluster with NCSExpert for the I-ABS 2.

Laid out the wiring harness and components on the bike and hooked up the Left/Right Handlebar switches to see if the buttons are working.

Trip and blinker/cancel button work.
ESA is not connected but I think it wont be a problem.
I didn't test the horn (too late at night).
Attached Images
File Type: jpg Checking Handlebar switches 1.jpg (35.4 KB, 38 views)
File Type: jpg Checking Handlebar switches 2.jpg (38.8 KB, 29 views)
File Type: jpg Checking Handlebar switches 3.jpg (43.1 KB, 28 views)
File Type: jpg Checking Handlebar switches 4.jpg (43.3 KB, 28 views)
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Old 04-18-2017, 12:33 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Awesome. If you have the time, a step by step description of how you did this would be very helpful to some members.
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  #10  
Old 04-18-2017, 12:57 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

I'll keep posting updates...... and have a detailed summary write up when its finished. I am still gathering parts, so its not going to be a 3 day job.
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Old 04-19-2017, 09:27 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Removed all the fairings and tank....

Started unplugging the Main wiring harness and the Engine wiring harness.

Thanks K-Man for checking the footbrake......
Attached Images
File Type: jpg Dismantle 1.jpg (33.8 KB, 37 views)
File Type: jpg Dismantle 2.jpg (40.8 KB, 30 views)
File Type: jpg dismantle 3.jpg (36.8 KB, 27 views)
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  #12  
Old 04-20-2017, 05:42 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Short video clip on the ABS removal / I-ABS 2 install.....

https://www.youtube.com/watch?v=FtTwIVdCVCQ&t=18s
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  #13  
Old 04-20-2017, 12:24 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Finally got the old Main Wiring Harness out and installed the new one.....

WHAT A FUCKING NIGHTMARE !!!!

Had to remove the cooler halfway to get to the SLS line
The manual says: "Unclip cooler and remove SLS line"

Even then, getting the 2 ZFE plugs past the injector cables was a shitfight.

I decided not to install the 07 Engine harness. No point in having an Oil level sensor if the tank doesn't have the hole for it. And I am not keen on drilling one either.....

First time that I've had all modules and both wiring looms hooked up together. Everything works, ESA, Lights, Horn, Blinkers, Heated grips.....

Pretty confident that everything will be ok once its done.

So far, without counting the time for researching this project (ebay, internet, wiring diagrams etc) I am up to 26 hours of Labour (having to label everything and comparing plug by plug).
Attached Images
File Type: jpg ZFE Plug removal.jpg (93.5 KB, 43 views)
File Type: jpg ZFE Plug removal 2.jpg (99.8 KB, 38 views)
File Type: jpg ABS Removed 2.jpg (67.6 KB, 35 views)
File Type: jpg ABS Removed.jpg (79.1 KB, 36 views)
File Type: jpg ZFE Recoding for Brake via Can.jpg (185.9 KB, 33 views)
File Type: jpg Lights Test.jpg (88.9 KB, 32 views)
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  #14  
Old 04-20-2017, 12:28 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Well, now I know just how electronically challenged I am. Makes my repair and maintenance work seem very, very basic. How did you learn how to do this? How were you able to recode the computer modules to work with the different abs modulator?
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Old 04-20-2017, 12:46 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Learning by doing......

And yes, to make this work the ZFE and Instrument cluster need to know where and from what kind of ABS the signals are comeing.

Reading the code in plain text is not too bad if you speak german, but there is also a program called NCSDummy that translates everything for you + shows you other options besides "active or not_active"

I did spend numerous hours looking at the wiring diagrams, comparing a 05 to an 07 harness setup. Its all the same, except for the Servo ABS vs. I-ABS 2.

Even the handlebar switches are exactly the same, except that now my red warning blinker button is dead.... I have to press both indicator pedals to get the warning blinkers going....
The Red button is now the BC (Board computer)
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  #16  
Old 04-20-2017, 01:38 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

This could come in very handy the next time my ABS module fails (already happened once) on my '06 K1200S. Would appreciate any and all details for this conversion. Thanks for posting!
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  #17  
Old 04-21-2017, 04:21 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Will give a detailed write up once finished. Including parts required.
I am waiting now on parts from the US (Speed sensors and ABS ring).....
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Old 04-21-2017, 04:37 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Quote:
Originally Posted by bobby
Well, now I know just how electronically challenged I am. Makes my repair and maintenance work seem very, very basic. How did you learn how to do this? How were you able to recode the computer modules to work with the different abs modulator?

These Bavarians are clever buggers thats why they build the best bikes in the world
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Old 04-23-2017, 11:37 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Hello all,
I am new to this forum and a proud owner of an 05 K1200S. I am a bit worried about all I am reading regarding the imminent failure of the brakes. I have two questions:
1) What happens when the brakes/servo fails. Do I still get a chance to stop, albeit a longer distance or is it an inevitable crash.
2) Although I am competent DIY work, it is no longer practical for me to do so. The main reason being that where we live now (retirement village), due to bylaws, I am not allowed to carry out work. I like the idea of removing the servo as Patrique has outlined. Is it worth while asking a dealership to carry out this work?
Regards,
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Old 04-24-2017, 04:32 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Hi Larry...

The work described here is very complex, and requires a lot of equipment. All the dealers I know would refuse to do it, due to possible complications later on (liability in case of an accident etc).

Even if you could find one, the cost would be more than the bike is worth - look at the posts above - 26 hrs labour so far (probably more by now!).

To answer your questions - the braking ability you are left with isn't as much as the full working system, but it's better than nothing - you do still have some stopping power. If your hands can grip hard enough, you'll be able to stop almost as well as with the full working system, but the pressure you'll have to apply to the lever is considerable - what catches most people out is that they apply the 'normal' amount of pressure to the lever, and only realise too late that it's not doing as much as it needs to. If you prepare yourself mentally for such a failure, and remind yourself often that you'll need to brake harder if/when this does happen, there's far less chance it will be a problem if the worst does happen.

You happen to be in one of the better places for this issue. On the older style ABS systems (which you have) the more common failure mode is for the pressure relief valves to stick (due to rusting, caused by moisture in the brake fluid). As Australia is fairly dry, you probably don't get as much rust as us Europeans do. Preventative maintenance helps here - get the dealership to change the fluid in the brake systems, including flushing the ABS unit.

If you're still uncomfortable with the bike due to this ABS issue, the answer is to change the bike. Sell this one, buy a similar bike made after 2007 (the ABS unit was changed to one that still gives full braking ability when it fails, just without the ABS part).


Regards,


Steve
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Old 04-24-2017, 10:14 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Larry. I had an 06 k12s that the abs failed. The power needed to stop the bike was like the old days before there was hydraulic disk brakes. So really not difficult, just more effort.
Based on the poll on this site, approximately 5 % of respondents reported an abs failure for K12 bikes. That number is bias of course because those with an abs failure disproportionately responded to the poll. The real number in cosiderably less than that. So the chance you'll have a falure are pretty low. You can reduce the chance by getting the dealer to flush the circuits every 2 years. Actually, the wheel circuits should be seviced every year and the brake circuits every other year, if my memory serves me right.
Steve suggested trading up to a k13s if you you're really concerned about this. I would add that there are a lot of reasons to replace this bike with a k13s. BMW made many small but significant improvements with the k13s. Well, well worth spending a little more to get one.
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Old 04-26-2017, 04:11 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Hours worked 40.....

New brake lines are in and I managed to bleed the system the "old school way"
Pushed about 800ml through (recycling what came out of the calipers).

I've been trying to get the pump to run for the bleed procedure using EDIABAS ToolSet32, but no luck.....

1.Error: Coding_Error
2.Error: CPU_Argument

VIN number is showing correctly in INPA/AIF..... So, no clue whats wrong.

Will have to figure the that out eventually.

Reassembled the fuel rail and installed the Airbox.

The fuel tank now won't go in the normal way because of the ABS-Plug......
The 07 onward tanks are slightly different in shape (where the ABS sits).
Now i have to unscrew the fuel tank holding bracket and pull tank+bracket out at once, making it a bit tricky to get to the fuel/electric plugs.

Also, the AuxPower plug (harness side) is different now. Lucky that i had one laying around.


Tmrw, I'll fill the radiator so i can run the engine and slowly ride the bike up the street........yay

I am still waiting on the front and rear speed sensor, and the front ABS sensor ring. Should be here in the next day or 2.
Attached Images
File Type: jpg power outlet.jpg (47.9 KB, 22 views)
File Type: jpg Tank difference.jpg (77.9 KB, 19 views)
File Type: jpg ABS block under tank.jpg (98.2 KB, 18 views)
File Type: jpg 80 percent complete.jpg (104.1 KB, 21 views)
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Old 04-27-2017, 03:40 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Nearly done.....

I decided to make it a video, rather then a write up.
Enjoy!!

https://www.youtube.com/watch?v=1_Q6...ature=youtu.be
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Old 04-27-2017, 12:29 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Thanks Patrique. Good video and commentary. I have to hand it to you for tackling such a daunting project. I probably would have thrown in the towel early on. Looking forward to seeing the bike once you get the new ABS sensors and ring installed.
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Old 04-30-2017, 12:29 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Update on the I-ABS 2 installation.....

Unfortunately, even with all the research and comparison i did over the last few weeks/month, I missed the fact that the Final drive housing and crown wheel inside is different.

The 07 onwards housing has a larger diameter hole for the speed sensor.
The 07 onwards Gear/Crown wheel has 48 slots for the abs sensor pickup.
The 05-06 has 78 slots..... crap!!!!!!

So, I now bought a used 08 final drive with a few external paint scratches and will be fitting that....... AHHHHHHHHHHHHHHHHHHHHHH

Even having to buy the final drive, I should still break even with all the components removed and then selling them on stealbay.

So far (in Australian Dollars):

$150 07 Wiring Harness (Both, but only needed the main one)
$150 Brake lines
$25 ABS Module tray
$50 ABS Module <-----Thats right, what a bargain that was. And it works!!
$65 ABS Sensors
$60 ABS Sensor Ring frontwheel
$530 Final Drive Unit
---------------------------
AUD $1030 total


Obviously, I can't add the labour cost..... Otherwise I'd have to cry
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Old 05-01-2017, 05:33 PM
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Re: Servo Assisted ABS Removal - I-ABS Install

Amazing stuff Patrique!!
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Old 05-10-2017, 03:51 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Still waiting on on the final drive to arrive from USA.....

Funny how stuff gets shipped around the US.

From California to Nevada to Colorado to Nebraska to Kentucky......and now the tracking has stopped because its international and Fedex only has a Domestic Label track on it. So it could be here tmrw or in 10 days....arghhhh.

I hate riding around without a speedo.
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Old 05-18-2017, 02:45 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Hey Pat, i know you can't get pictures on your phone, are any of these bits what your after. The bit on the end of the axel has a small love bit in it, but nothing serious and not cracked.





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Old 05-18-2017, 04:11 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

New (used) final drive arrived yesterday..... It has few scratches on the lower side, but can't be seen from top.

Installed it, inserted the new type Speedo Sensor and replaced the oil.

And I thought from now on its going to be plug and play. NO NO NO NO!!!

I got on the bike, rode down my driveway.....
Brake Failure Light blinks and turns off.

Had the biggest smile for the next 50 meters.....
Slightly hit the front brakes and the lever starts pulsating. No braking power at all. I can now hear the ABS pump motor running.
Brake Failure LIGHT SOLID ON....... AHHHHHHH.

Back to the garage..... Hooked the bike back to computer and used Ediabas Toolset32 to access the I-ABS2.

"Front wheel sensor speed unplausible"
"Failure would cause warning light to come on"

Awesome..... I totally forgot to adjust the space between the ABS sensor ring and the Sensor.

The servo assisted brake sensor has 4mm gap between the Ring/Sensor
The new I-ABS2 has a 1.2-1.4mm gap. (Thanks Kiwimat for measuring)

Removed the calipers and pressed the pistons back in.
Loosened both ends of the Axle
(Left side too, the one you should never touch)

Using a plastic hammer I tapped the axle/wheel assembly to the left by about 2.5mm (see picture).

Gap is now somewhere between 1.2-1.4mm (didn't bother to measure).

Unfortunately, but its only cosmetic, the axle spacer sticks out by about 2mm.

Calipers back on to the bike..... Slowly pulling the front lever to press the pistons back on the pads/disc. (5 pumps and they were solid)


Deleted the error codes and reset the ABS Module.

While i am at it, I recoded the Instrument Cluster, the ZFE and BMSK to enable ASC.

Yep..... The ASC function is controlled by the ABS module. So, if your bike doesn't have it (2007), then get yourself an ABS module from a K1300 and happy days. Not having the button on the handle bar to turn it off doesn't mean that it can't be added.

Unpluged the bike, short prayer and off I go.


I-ABS 2 + ASC on a 2005 K1200s works


THE END....



PS: Hours...... don't know. Maybe 60-70?!
Attached Images
File Type: jpg image1_1.JPG (634.9 KB, 19 views)
File Type: jpg image2_1.JPG (619.0 KB, 19 views)
File Type: jpg image6.JPG (271.2 KB, 33 views)
File Type: jpg image3_1.JPG (695.4 KB, 21 views)
File Type: jpg image4_1.JPG (421.0 KB, 25 views)
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Old 05-20-2017, 07:37 AM
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Re: Servo Assisted ABS Removal - I-ABS Install

Update:

The ABS function is working, but ASC isn't.... Error when detecting wheelspeed.
ASC is internally switched off (no ASC warning).
Its either because the BMSK doesn't understand the wheel speed or I have made a mistake coding the BMSK. There is 3 Variants of ABS that the BMSK can be set to.

At the moment, its set to ABS type Value 3.
Value 1 was the original setting (Servo Brake).....

Maybe its 2?

To be investigated....



My SERVO ABS UNIT is for Sale on Ebay..... So for all of you that have the old type setup and wan't a good spare one on shelf:

http://www.ebay.com.au/itm/K1200s-K1...IAAOSwKytZH7X5
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  #31  
Old 08-03-2017, 03:17 AM
hondakiller hondakiller is offline
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Re: Servo Assisted ABS Removal - I-ABS Install

Quote:
Originally Posted by Patrique83
Update:

The ABS function is working, but ASC isn't.... Error when detecting wheelspeed.
ASC is internally switched off (no ASC warning).
Its either because the BMSK doesn't understand the wheel speed or I have made a mistake coding the BMSK. There is 3 Variants of ABS that the BMSK can be set to.

At the moment, its set to ABS type Value 3.
Value 1 was the original setting (Servo Brake).....

Maybe its 2?

To be investigated....


The correct parameter must be "2"

I did the BSMKP reading of two bikes with ASC as standard
And the first line is so in the two:

ABS_LIEFERANT
Wert_02

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  #32  
Old 08-03-2017, 08:20 PM
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Patrique83 Patrique83 is online now
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Re: Servo Assisted ABS Removal - I-ABS Install

I will try it when i get my bike back.
Thank you
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  #33  
Old 08-04-2017, 09:55 PM
chucky1978 chucky1978 is offline
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Re: Servo Assisted ABS Removal - I-ABS Install

Good Work... But

http://www.i-bmw.com/attachment.php?...7&d=1495094985

DO NOT DO THIS !!!


Sorry my english ist very bad :

The chassis geometry of the vehicle is thus greatly changed.

It is better to change the brake disk:
With washers, or use Brembo retrofit brake discs (68B407D7) with Floater (105577615) that do not have an step at the mounting holes, as is the case with BMW original-Discs.
(https://picload.org/view/rwdwrlaa/bmworiginal.png.html)
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  #34  
Old 08-10-2017, 11:44 AM
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Patrique83 Patrique83 is online now
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Re: Servo Assisted ABS Removal - I-ABS Install

The original BMW disc on a 2005 K1200s is a floating disc.

I had to loosen the front axle and shift it to the left to adjust the gap between ABS Sensor ring and sensor. The gap in the photo is minimal and the bikes geometry has not been affected. It runs straight, and the tyre is not wearing on one side....
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  #35  
Old 08-23-2017, 09:37 AM
hondakiller hondakiller is offline
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Re: Servo Assisted ABS Removal - I-ABS Install

Today I activated the ASC in a 2009 k1200r with ABS2
And despite putting all the correct values in the BSMKP and in the KOMBI
ASC does not work

It may be that the ASC button on the handlebars is necessary
Or maybe something more is needed than at present I do not know

Soon we will take that bike to the dealer to see if you need any software update in the BSMKP or is because it lacks the ASC button



Here I leave you the list of a BSMKP of a motorcycle with ASC of origin

BMSKP
----------------------

ABS_LIEFERANT
wert_02
ASC_BEREIT
aktiv
ASC_VERBAUT
aktiv
GS_SETTING
nicht_aktiv
OELNIV_SENSOR
aktiv
OELTEMP_SENSOR
aktiv
RAD_RADIUS
190/50_17
default
UEBERSETZUNG
k40
k44
OELNIV_LOW_HIGH
nicht_aktiv
----------------------
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  #36  
Old 08-25-2017, 10:25 AM
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Patrique83 Patrique83 is online now
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Re: Servo Assisted ABS Removal - I-ABS Install

Did you activate ASC in the ABS?
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  #37  
Old 08-26-2017, 04:27 AM
hondakiller hondakiller is offline
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Re: Servo Assisted ABS Removal - I-ABS Install

In ABS there is no reference to ASC



EEP-ZEILE_01
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_02
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_05
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_06
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_07
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_08
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_09
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_10
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_11
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_12
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_13
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_14
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_15
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_16
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_17
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_18
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_19
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_20
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_21
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_22
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_23
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_24
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_25
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_26
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_27
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_28
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_29
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_30
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_32
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_33
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_34
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_35
k25
k26
k28
k40
k43
k44
sonst
EEP-ZEILE_36
k25
k26
k28
k40
k43
k44
sonst
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  #38  
Old 08-26-2017, 11:11 AM
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Patrique83 Patrique83 is online now
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Re: Servo Assisted ABS Removal - I-ABS Install

SORRY.... my mistake

Did you code "FA" W650 AUTOSC/ASC into all modules?
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  #39  
Old 08-26-2017, 03:01 PM
hondakiller hondakiller is offline
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Re: Servo Assisted ABS Removal - I-ABS Install

Quote:
Originally Posted by Patrique83
SORRY.... my mistake

Did you code "FA" W650 AUTOSC/ASC into all modules?

I think if, on Friday I will have the bike again and I will review it
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