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  #61  
Old 07-17-2013, 11:28 AM
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Re: Repair your own defective K1200GT ABS pump

A customer brought his K 1200 in with the brake failure light on. Thanks to all the post I went straight to the problem. Took the motor apart just like everyone has done. Brushes were to far gone to fix. Sent it to ModuleMaster. Very nice people to deal with. Quick turn a round. The bike is fixed and I have a five year warranty. If you can un stick your brushes great. But in my case I need help.
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  #62  
Old 07-17-2013, 12:13 PM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by RFW
THEY WON"T! This is simply nonsense. Brushes in an electric motor don't just "crumble".
I have seen that occur in automotive applications (alternators, etc.) that are exposed to high heat, current, etc. An alternator is not a motor but brushes are brushes. This kind of failure may or may not be likely with the brushes in the ABS pump motor and I have no idea whether that particular claim is BS or not, but it certainly can happen.
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  #63  
Old 07-29-2013, 05:29 PM
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Re: Repair your own defective K1200GT ABS pump

I wound up doing this repair for the second time in 4 months this weekend. I didnt open up the brush holders enough the first time and one of the brushes stuck again. I'm chalking it up to being too cautious about damaging something. It's easier the second time around.
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  #64  
Old 07-30-2013, 03:10 PM
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Re: Repair your own defective K1200GT ABS pump

http://www.youtube.com/watch?v=oyUvwwBQg0A
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  #65  
Old 07-31-2013, 05:49 AM
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Re: Repair your own defective K1200GT ABS pump

You can buy motor brushes from many suppliers. You need the dimensions and new length (often 'standard' rectangular sizes), some knowledge about the composition e.g from very hard copper composition to very soft carbon and the type of 'tails' - usually copper braid. If you tell a brush supplier what current the dc motor takes, they can often advise on brush composition most suitable.

I agree with Bob that brush sticking is most common. The reason is they try to keep the minimum of spring tension on the brush to get minimum motor commutator wear. Unfortunately, as the brush wears it throws up dust into the brush holder making the brush stick.

Another issue is they often make the brushes with very square sides, whereas the holder it slides in is formed from brass with rounded corners. All you have to do is gently round off the corners of each brush with a file and it should stop sticking.

To help others, if you think you have brushes that are just stuck and you feel they are not worn (I think they should project just above the brush holder). Please measure the brush dimensions and post a photo. You can get some idea of the brush composition by rubbing the brush on paper. Very soft carbon will leave a heavy black line and copper mixes a fainter line.
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  #66  
Old 07-31-2013, 11:37 AM
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Re: Repair your own defective K1200GT ABS pump

Just a side issue, light tension does not lead to long brush life. In general, 2.5 lbs per square inch is ideal for most uses. It leads to ideal commutation conditions. Brush holder tension was always part of the maintenance of the motors and generators I was responsible for for many years. And as mentioned the occasional holder needed the brush physically fitted by sanding on non corundom paper. Many times the faulty brush was being held back by means of its pig tail hanging up. There is a sweet spot for brushes in the tension threshold. You want the minimum friction for good brush wear, in a carbon brush this is found with a brush running hot, about 150*F if I can remember it might be more. At this point the graph starts showing minimal friction and thus good life. On something like our use, the brush is probably not going to get that hot because use is sporadic. But you do need firm contact rather than light bouncy touching. And the correct tension promotes good brush action in the holder which this thread is all about.
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  #67  
Old 07-31-2013, 12:37 PM
voxmagna voxmagna is offline
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Re: Repair your own defective K1200GT ABS pump

Good points!

But I can't help thinking that something must be wrong with the BMW design if brushes are sticking. Unsticking them does not really solve the problem for good. I would agree that with infrequent motor use, I would expect the brush length to be as new with very little wear on the length and for there to be very little brush dust. Something sounds wrong with the fit of the brush in the holder, which lead me to suspect the brush/holder profile compatibility. Have they plated the brush holders and can it get any surface weather corrosion? Is there any evidence on the sides of the stuck brushes of disimilar metals in contact? It is rare to use entirely carbon in the brush mix as they want low resistance. I would expect some copper. Copper and brass are similar so no probs there, but copper and plated steel + some humidity/moisture - ugh! Normally the holders are plain brass, but these days they make everything from cheapo steel and electroplate to look like brass. If the holders are magnetic they are not brass! I have also come across the tails fouling and that should be checked here.

If the application is for intermittent use and we are not finding brushes worn down, then maybe increasing tension is better? I can't see what they do here, but normally brush tension is provided by a circular concentric spring. In theory that should give the most consistent tension from full new length to shortest worn out length (usually when the tension spring hits the holder).

This was posted earlier in the thread, so perhaps the motors are not so intermittent use or they take a whacking high current and the brushes are not up to it?

Quote:
Took the motor apart just like everyone has done. Brushes were to far gone to fix.

When you think the fuel pump on these bikes run for hours and many miles, there must be something wrong for these intermittent use d.c motors to fail like this.
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  #68  
Old 07-31-2013, 12:59 PM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by voxmagna
When you think the fuel pump on these bikes run for hours and many miles, there must be something wrong for these intermittent use d.c motors to fail like this.
Being used so rarely probably has something to do with it, along with a poor design.
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  #69  
Old 08-02-2013, 06:50 PM
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Thumbs up Re: Repair your own defective K1200GT ABS pump

Gentlemen, let me just say that this thread is what makes i-bmw such a great community. You guys were brilliant at finding out that the brushes were the problem in the first place plus figuring out how to get into the sealed motor and then to reseal it..Fantastic. Thanks to all of you.
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  #70  
Old 11-22-2013, 04:57 PM
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Re: Repair your own defective K1200GT ABS pump

This is a FANTASTIC post. I love fixing what most people say cant be fixed!

Thanks to all that have posted the cool pictures and all the great instructional write ups.

Bill
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  #71  
Old 12-03-2013, 03:42 PM
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Re:I Repair your own defective K1200GT ABS pump

Hi Dennis
Thanks to your delving into this ABS Modulator debacle that BMW are putting us though,
I continued to read all the other helpful post's and decided it was time to man up and have a go.
As I have had the tank off on a number of times and am quick at it now, in my best going out clothes complete with white shirt, attacked the project.
With in 1 hour the ABS could be turned on and off and I also regained the proportionate link between front and rear.
Celebrations every where. I have attached a photo showing where I drilled a hole and sprayed brake cleaner followed by tapping with a rubber hammer the cylindrical housing.
It took 3 applications of spray and tapping to have it work successfully.
Attached Images
File Type: jpg photo.JPG (92.4 KB, 122 views)
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  #72  
Old 12-03-2013, 03:55 PM
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Re: Repair your own defective K1200GT ABS pump

I would have never thought to spray brake cleaner in.

I guess the cleaner soaks into the brush holders and, when tapped, washes away any built up graphite dust that has caused the brushes to jam.

However, I thought I read somewhere that the problem is that the brushes jam because somehow they are swelling up within the brush holder?

If your fix withstands the time, mileage and temperature test, you will be regarded as an i-BMW icon!!

Dennis
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  #73  
Old 03-02-2014, 04:39 PM
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Re: Repair your own defective K1200GT ABS pump

Two questions to an old thread.
1) How does one remove the bearing so that the section holding the brushes is more accessible?
2) 50/50 shot of breaking the tabs during drilling. From my perspective the tabs are not necessary. The power connection and the gasket would each prevent the motor from turning within the housing, and it's trapped between the housing and ABS module so it cannot possible separate. So if they break, no big deal.

Easy mod, but one big tip. Bleed the front master cylinder first, then the calipers. DAMHIKT.
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  #74  
Old 03-02-2014, 05:45 PM
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Re: Repair your own defective K1200GT ABS pump

I just sent you a private message with my phone number so we can discuss on the phone.

Dennis
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  #75  
Old 03-02-2014, 11:41 PM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by millers
Being used so rarely probably has something to do with it, along with a poor design.

Not so! The pump starts and runs EVERY time the front brake lever is activated when the bike is in motion. Applying the front brake lever activates the front brakes (naturally!!), but it also starts the pump (when the bike is in motion) which supplies the hydraulic pressure needed to activate the rear ("linked") brake caliper.

To see this in action, put the bike on the center stand, and switch on the ignition (don't start the bike). Now, spin the rear wheel manually, and when is it still moving, apply the front brake lever. The pump will start for a split second and the rear wheel brake will actuate and the rear wheel will stop instantly.

As for "poor design", a set of brushes that are VERY slightly too big and occasionally on a small percentage of bikes get stuck in their brush holder, may be irritating, but is hardly an example of overall poor design. This annoyance aside, this ABS system is the best performing ABS BMW or any other bike company has made.... best by far!
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  #76  
Old 03-03-2014, 07:43 AM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by RFW
Not so! The pump starts and runs EVERY time the front brake lever is activated when the bike is in motion. ...
I've been watching and waiting months for someone to finally say that! Thanks !!

What say ye about ignoring the broken tabs on re-assembly? I see no possible way that they have a purpose other than during the manufacturing and shipping process. Once assembled the cover and motor are a sealed unit.


But it is a poor design on the brush holders. Far too many overall K and R series brush failures on the internt. It's more widesprad of an issue than it should be.
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  #77  
Old 03-03-2014, 07:52 AM
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Re: Repair your own defective K1200GT ABS pump

The pump motor is a commodity item, produced by ATE, a long-standing supplier to BMW.

As I see it, the only gotcha is the means by which you retain the motor to the pump body.

You will note that in my rebuild, I peened over a small amount of alu from the original retaining lugs to retain the rebuilt motor.

Other folks have used plastic metal, putty or adhesives - can you be 110% confident that they will not shrink, crack or break loose ?

If that were to happen, the motor COULD detach from the pump body.
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  #78  
Old 03-03-2014, 12:43 PM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by chopper_h
The pump motor is a commodity item, produced by ATE, a long-standing supplier to BMW.

Yes, it is a commodity motor, but no, it's not made by ATE!

ATE (or "Alfred Teves GmbH") doesn't make motors. They make braking systems (including the latest BMW ABS system). Like any specialist company, they buy the electric motor from a company that specializes in making electric motors.

A similar situation is with the older servo ABS system. It was made by another brake system specialist "FTE". who purchased the electric motor in that system from "KAG", a Swiss motor manufacturer.

Quote:
Other folks have used plastic metal, putty or adhesives - can you be 110% confident that they will not shrink, crack or break loose ?

You're right.... this will not be reliable! As you say (and as some others have done also), peeninig over the alu body is the only sensible option here.
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  #79  
Old 03-13-2014, 08:21 AM
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Re: Repair your own defective K1200GT ABS pump

Well coming up two years after my ABS repair the dreaded red light of death as reared its ugly head again.
I used Chemical Metal and it's still as secure as the day it went on.
This time I will probably use low heat aluminium brazing rods (durafix) or such like)
Still considering putting in a used ABS module but still well expensive.
Has anyone here actually replaced the brushes ?
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Old 03-13-2014, 03:09 PM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by urbster
Still considering putting in a used ABS module but still well expensive.
Contact our Site Supporting Vendor, Module Master, for a rebuild of your unit. Cheaper than replacing it.

http://www.modulemaster.com/en/services/index.php

Mention you heard about them on I-BMW.
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  #81  
Old 03-22-2014, 10:51 AM
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Re: Repair your own defective K1200GT ABS pump

I'd like to thanks all users of this forum for the clear instructions about the ABS problems.
I just fixed my ABS. My bike is an R1200R my 2007.
First, sorry for my bad English, if some one don't understand some word please sorry.
About 10 days ago in my R1200R appear the ABS light! My god, I was very angry.
Than I went to my Bmw dealer: he tells me that for a new ABS and for the work I must spend about 1500 euro.
For this reason I fixed to myself the ABS.
If someone want to see some pictures of my work, I will post here in next days.
P.S. To open the electric motor I used a dremmel, and in this way it was very easy
Thanks
Ciao a tutti
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  #82  
Old 03-22-2014, 11:17 AM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by anding
I'd like to thanks all users of this forum for the clear instructions about the ABS problems.
I just fixed my ABS. My bike is an R1200R my 2007.
First, sorry for my bad English, if some one don't understand some word please sorry.
About 10 days ago in my R1200R appear the ABS light! My god, I was very angry.
Than I went to my Bmw dealer: he tells me that for a new ABS and for the work I must spend about 1500 euro.
For this reason I fixed to myself the ABS.
If someone want to see some pictures of my work, I will post here in next days.
P.S. To open the electric motor I used a dremmel, and in this way it was very easy
Thanks
Ciao a tutti

Andrea,
A big welcome for your first post here. We have riders from all over the world (USA, Canada, UK, Germany, France, Italy, Australia, New-Zealand and more...)

YES, it would be very useful if you can post text and pictures of your ABS module repair. The more we have, the more riders you can help figure out how to do it.

Also, we love motorcycles and trip pictures here. I see in your profile that you are from Italy, thus I am sure you can show great scenery and gorgeous women ;-)
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  #83  
Old 03-22-2014, 11:24 AM
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Re: Repair your own defective K1200GT ABS pump

Thnanks Sailor. I will try to post my pictures Monday.
Ciao
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  #84  
Old 03-22-2014, 02:19 PM
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Re: Repair your own defective K1200GT ABS pump

anding

WELCOME to the Forum!!! Your English is fine.

Well done on repairing your own ABS Pump Motor. Excellent Job!

Anxiously awaiting your repair pictures.



I also have an 07 K1200R.

Bill
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  #85  
Old 03-24-2014, 07:03 AM
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Re: Repair your own defective K1200GT ABS pump

Hi guys, here some pictures of my work. In these pictures you can see my work with dremmel. Using dremmel I have not damaged the plastic tabs.
















The problem of my electric engine was only a problem of oxidation of the rotor (maybe)...
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  #86  
Old 03-24-2014, 10:26 PM
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Re: Repair your own defective K1200GT ABS pump

Excellent Pictures!! Well done! Enjoy the saved cash!

Bill
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  #87  
Old 03-25-2014, 08:24 AM
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Re: Repair your own defective K1200GT ABS pump

I'm back with the modification that was buzzing in my head. Today I removed the tank and side covers and I insert (without remove the modulator) this band safety: now I'm more relaxed. As you can see from the picture I put a thin sheet of metal "L" at the plastic part (as opposed to the electric motor) to avoid friction with the metal clamp. With this I declare finished the job, I hope at least for the next 10 years! Eh eh




See you soon...
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  #88  
Old 04-07-2014, 03:06 PM
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Re: Repair your own defective K1200GT ABS pump

A few months ago I had to fix the motor for the second time because after 1 year the same errors returned.
So I hope cleaning your rotor will do the job (I doubth that)

If you would like to secure your motor to the hydraulic part of the ABS unit, you could use a much better way.

Drill very carefully small holes (not deeper than 7mm!!!) and with 3,3mm (millimeter) So you can make screw thread into the holes
Then you can use short M4 bolts and spacers which are slightly adapted and drilled to keep the motor in place

I hope this picture shows the right details.
Drill only in the higher parts of the unit to prevent damage to the unit, which could make it worse!!!!



topview:



Instead of repairing your pumpmotor you can also search for a motor replacement from a car ABS unit.
(I found a similar pumpmotor from a BMW car which fits well and does the job very well)
See the different part numbers printed on the motor.
You can use this numbers when you have to google for a suitable replacement motor.

Regards,
Ted
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Old 04-07-2014, 05:23 PM
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Re: Repair your own defective K1200GT ABS pump

Excellent work damted. For me now it's impossible to drill the higher parts, because I deformed it with a hammer.
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  #90  
Old 04-08-2014, 03:44 AM
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Re: Repair your own defective K1200GT ABS pump

Interesting, after the initial project on the K12 of my wife, I now have an easy process for repairing K12/13 iABS2 pump units for customers.

The project to install hex-head fixings is not difficult if you have a pillar drill - Damted is very cautious, I can confirm that you have PLENTY of metal to work with.

The upper fixings are M4 x 12, and lower fixings are M5 x 10

The drill sizes you need are : M4 = 3.3mm, M5 = 4.2mm.

Use tape to mark the drill depth, 11mm from the tip of the drill.



Cover the pump ports with gaffer tape.
Centre punch the starting points and use a pillar drill, or drill carefully by hand - 3.3mm upper, 4.2mm lower.







Start off with an M4 taper (aka starting) tap, ensure it is at 90' to the pump body.
The upper hole should be followed through with an M4 plug (aka bottom) tap, to ensure the thread is cut to the bottom of the blind hole.



The lower fixing holes are in line with the ABS bracket mounting holes so there is no danger of drilling too deep, and can easily take the M5 bolt.




Two M4 and two M5 penny washers bent to form clamping plates.


Penny washers bent to form clamping plate, M5 washer ground flush at RH edge.


Penny washers bent to form clamping plate.


Unit fitted, pump can be repaired without need to remove iABS unit.
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  #91  
Old 04-08-2014, 05:25 AM
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Re: Repair your own defective K1200GT ABS pump

Well,,,,,,,,,, As luck would have it, or better yet,, Murphys Law, Yesterdays drive to work was greated with the RED GLARING Brake Failure lamp.

So,, I guess i have some work to do.

damted

How much money did that new motor cost?? Looks like that may be a good option. How did you search E Bay for it?

Thanks

Bill
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Old 04-08-2014, 03:07 PM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by Bill Curlee
Well,,,,,,,,,, As luck would have it, or better yet,, Murphys Law, Yesterdays drive to work was greated with the RED GLARING Brake Failure lamp.

So,, I guess i have some work to do.

damted

How much money did that new motor cost?? Looks like that may be a good option. How did you search E Bay for it?

Thanks

Bill

Hi Bill,

I found a BMW car ABS unit on a second hand site (marktplaats.nl) for about $100,-
I only had to remove the motor and put it on my BMW ABS module.
I tested the "new" motor directly on 12V (It draws about 4 Amps on 12V)
this testing gives a nice sound

If you search on ebay for recent Teves ABS units and look well at the motor assembly and the similarity of the motor it should work.

A quick search on ebay:
I am not exactly sure if this unit has the same pumpmotor, but for other pictures you could ask the seller:
http://www.ebay.nl/itm/130386812139

This one comes from the UK.

If you want to find other modules you could enter the numbers which are on the motor
3451-6790146-01 (BMW unit) or:
AE81-2C405-AD (brand FoMoCo from a Ford Fiesta mk2011) (this one took a long time to discover, but it costed me only $75,- (including shipping from the USA)

So I even have another spare motor in stock.

Good luck with your search and let us know how you succeed!
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Old 04-08-2014, 03:53 PM
chopper_h chopper_h is offline
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Re: Repair your own defective K1200GT ABS pump

Good catch - I would never have thought that the Ford Fiesta has the same pump motor for £50.

Sh*t, it even looks like the same pump unit, but of course will not function on a K12/13 !!!

A Ford unit will cost a LOT less than BMW from breakers yard
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Old 06-29-2014, 03:37 PM
Rsportxema Rsportxema is offline
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Re: Repair your own defective K1200GT ABS pump

Hello everybody, I'm new in this forum.
I'm from spain and I have k1200 Rsport 2008 and I have the Same problem that you.
I need disassembly the roller to can change the brushes.
How I can disassembly the roller?.
Where I can buy a new compatible brushes?
The last year I cleaned the brushes but the problem has return to my bike.
Thanks in advance.
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Old 06-29-2014, 05:26 PM
chopper_h chopper_h is offline
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Re: Repair your own defective K1200GT ABS pump

I will gamble €50 that you have not opened the brush holders sufficiently.

use a fine scaplel blade or jewellers screwdriver and open up the metal cage which holds the brushes.

Strip the motor again, and work on the brush holders to ensure they brushes move freely.

Before reassembly, hold the motor base plate and move the rotor around in 360' circles - you should see the brushes move in/out as you do.

Repeat this for 10 minutes to ensure that constant motion of the brushes does not cause heat and sticking in the 'out' position
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Old 06-30-2014, 01:21 AM
Rsportxema Rsportxema is offline
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Re: Repair your own defective K1200GT ABS pump

Thanks chopper h but I can see mover the brushes.
Last year I put oil to electric contact and cleaned the brushes.
I want to do something else.
If no next year I'll have Same problem.
I'd like change the brushes o remplace the pump for other to ford fiesta.
I need something more efective.
Have you do this operación?
I don't know how I can take out the roller bearing.
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Old 08-03-2014, 06:54 PM
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Re: Repair your own defective K1200GT ABS pump

Last week I got same steady light. Don't have access to reader so don't know exactly what the code is.
Took motor off with pump in place. Looked like one brush was separated or stuck back.
Cleaned it opened up a little the holder. tuned by hand a few turns. Gave it 12v after closing it up, spun and sounded right i guess. Added motor back to pump, JB weld a little and all looked good.
Now start bike up normal flashing light, rolled light off. Tried it a few times and BANG light back steady.

Guess I'm going to have to get the codes read, could be a different problem cant it?

thnx in advance
Raul
07 K1200gt 25k mi.
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Old 08-03-2014, 08:17 PM
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Re: Repair your own defective K1200GT ABS pump

I’ve had the dreaded ABS BRAKE FAILURE light on for a while and decided to troubleshoot the issue. I feared that it was the failed motor brush assembly issue.

I Purchased and received a GS-911. Plugged it in and ran a check for failure codes and low and behold, the root of the issue is a failed FRONT SPEED SENSOR. When the issue first happened, I was sure that I had the bad brush holder. I am so glad I had a purchased and used the GS-911 to figure out what was really wrong.

So,, I removed the right cover and do some troubleshooting.


I will spin the wheel and see if I get any voltage from it at the connector.

Glad that it isn’t the ABS motor issue.

So tonight, I took off the right air intake cover to inspect the wiring and conector and low and behold, there lies the connector apart! I plugged it back in and took the bike for a drive. The seconed that I started the engine, I knew it was fixed.

Instead of the BRAKE FAILURE light, I got the flashing brake light like we are suppose to. As soon as I rolled down the driveway, I had a normal instrument display VOID of nasty red lights!

See pics below:






The connector was clean and undamaged so I just had to snap it back together and its good to go


Bill

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Old 11-20-2014, 07:23 AM
paulmogs paulmogs is offline
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Re: Repair your own defective K1200GT ABS pump




Firstly, would like to thank every-one that contributed to this thread.
Saved me a heap of time in diagnostics.
I would not recommend this method of "freeing" the brushes!
The magnets in the electric motor are held apart by two U & W spacers; applying the "hammer & drift" (as pictured) could shatter the magnets.
This was done by PO or mechanic; (I use that word loosely)

Because of the time saved for me, I made a donation.

You know how it works? put $20 in the money jar, rattle the change in the bottom, and pull $50 out.

Its what I do; thank me later.
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Old 11-27-2014, 09:01 AM
voxmagna voxmagna is offline
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Re: Repair your own defective K1200GT ABS pump

I know this thread has been running a while and I've just caught up with some of the recent posts.

The excellent photos put up by Anding, Chopper h Et Al have just woken me up to something.

Last year I had the brake pressure sensor fail on my VW. The pressure sensor is pressed into the ABS fluid block and I didn't succeed in finding an alternative replacement or research how to remove and press one back in.

I was lucky and picked up a complete new ABS unit with motor for £130.

I learned the electronics module is replaceable, the pressure sensor is not without a machine shop. I never dived inside the motor, but externally it looked pretty substantial. Older VW's had the brake pressure sensor fitted inline and outside the (integral) ABS fluid block. These sensors are supposed to be rated for over 2000 psi, but constant flexing on the sensor bridge seems to cause regular expensive failures. Some have gone back to the outboard fitting of an in-line pressure sensor patched into the ABS unit electronics board and say it works. Some firms used to advertize this fix/repair, but I think ran scared of potential litigation problems.

Looking at these thread photos, the part numbers may be for the K1200 build, but the parts themselves, including the motor look very like the VW unit I bought. The 4 port valve body looks to have the fluid holes in the same place too.

My VW is a 2007 EOS, but Golfs use the same unit, I don't know about BMW cars. I can't say what parts 'may' be useable and there will always be risks unless you do your own research. I don't have a failed K12 pump to sort out either.

I expect the electronic module will be the units 'personality' and I doubt the oem VW electronic board would work, but once inside it is easy to change the board. Maybe BMW car units have a similar pedigree? Car ABS units will be more easily available and (relatively) cheap as chips.

Switching parts like the complete motor is easy and probably carries the lowest risk, provided some comparison tests are done on motor current draw, physical properties, dimensions etc.

Hope this helps
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  #101  
Old 12-21-2014, 02:53 PM
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Re: Repair your own defective K1200GT ABS pump

Stewart,
Thanks for your reply, an update, Kent Holt bless him did not chuck my module!!! Got it back from him and sent it to module masters and they rebuilt it for $250.00 so I now have a spare!! If any one is in need of a replacement I would consider selling it. It is a teves unit ABS II.
I did the cam chain guide myself and also upgraded the tensioner to the newer hydraulic type. The procedure is not difficult cost of the new bolts was pretty expenstve though.
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2007 Moto-Guzzi Norge 1200, 2009 Harley FLTRI, 2008 BMW K1200GT/4!! 2012 R1200GS. And have just re-acquired my old 1975 R90S that I put a turbocharger on in 1978!!!!! Also a new acquisition just bought a 14' R1200RT-WC, addendum!! Traded my '75 R90s Turbo for a 2008 Ducati Multistrada 1100S: my friend the gm of HD of WV WANTED it for his personal collection, so what could I do????
OK,Ok, I need Profesional Help, I admit it!!!
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  #102  
Old 12-21-2014, 04:14 PM
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Re: Repair your own defective K1200GT ABS pump

Did the installation of the new tensioner make any improvements in engine noise??

Was your chain excessively slack?

Thanks

Bill
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  #103  
Old 12-22-2014, 06:09 PM
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Re: Repair your own defective K1200GT ABS pump

Bill
I changed the chain tensioner only as a precaution, there was not Any excessive slack that I could tell and no abnormal noise. While installing the cam chain guard I also took up some slack in the oil pump drive chain as well. The bike had @ 18K miles on it and I decided a little preventive maintenance would alleviate any problems down the road so-to-speak!!!
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  #104  
Old 12-22-2014, 06:48 PM
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Re: Repair your own defective K1200GT ABS pump

Good info! When you tightened up the oil pump chain, did you do it with the clutch basket in place & how did you determine the proper tension?

I have to replace my clutch plates and have to install the up-graded chain tensioner and I plan on taking out some slack in the oil pump chain drive.

Thanks in advance..

Bill
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Old 12-25-2014, 11:38 AM
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Re: Repair your own defective K1200GT ABS pump

Well, after taking apart my ABS motor twice to free up sticky brushes, I sent it to Module Master. They did an excellent job. Great service, good price. I highly recommend them.
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Old 02-13-2015, 11:07 PM
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Re: Repair your own defective K1200GT ABS pump

The repair charge by Module masters is now $250.00!! I recently had the Teves abs on my 08' K1200GT replaced by my dealer at a cost of$1600.00 I got the defective module from him and sent it to MM and the repaired it and warrentied. It for one year for $250.00!!!
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Old 02-20-2015, 07:27 AM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by Beech
Put your photos in small pixel format into your photo gallery. Then you can open your post on the I-bmw site, and in another window your photo gallery pictures ("my photo gallery"). In your photo gallery click on one of your photos so it gets big. Then all you have to do is drag it to the curser in your window with the post your typing up. Make sure the curser is a line or two below your text. Then below the picture the curser will show up or maneuver it down and do another picture with the enter/return key ...and so on.



and more


all taken from a post on this site. Loose brushes.....




Here is a place that does the work.
http://www.modulemaster.com/en/index.php
Hi, I have disassembled the pump motor so far, is there a non - destructive way to remove the ball bearing to gain'real' access to the brushes to clean them and possible increase the freeplay of the guides ?

Many thanks
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  #108  
Old 04-25-2015, 12:30 PM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by dennismo
I am currently repairing my 2007 K1200GT ABS unit that has fault code "No power to ABS pump". The pump is repairable as the problem associated with this code is sticking brushes in the motor.

(This is the generation of ABS that does not power assist, but does emit continuous "clicks" when you activate the front brakes as it apportions a percentage of the front brake force to the rear.)

I have separated the pump from the ABS (to disassemble the pump and get at the motor brushes) but both the separation and reassembly is quite a nightmare and requires machine shop involvement. The ABS was not designed to taken apart.

However, I feel there is a way to access the brushes without taking the motor to bits. This involves strategically drilling access holes in the motor body and brush carrier plate to access the brushes.

Does anyone have a non functional ABS that I could have?? I am happy to pay for postage and will post my results if I come up with a successful procedure!

Thanks

Dennis
Hi Dennis. Are you able to chat now re this pesky pump
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Old 06-01-2016, 09:23 AM
Killa Meter Killa Meter is offline
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Re: Repair your own defective K1200GT ABS pump

Hey guys first post and sorry to resurrect an old thread but does anyone think I can remove the motor cover by removing the unit from the bike then drill the small holes to push the plastic tabs ,without removing the plate held on by the aluminium chiselled dimples, might save a lot of work (grief ) and it looks like I can still just access the brushes without removing the armature ?
Thanks in advance...
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Old 06-01-2016, 04:29 PM
millers millers is offline
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by Killa Meter
Hey guys first post and sorry to resurrect an old thread but does anyone think I can remove the motor cover by removing the unit from the bike then drill the small holes to push the plastic tabs ,without removing the plate held on by the aluminium chiselled dimples, might save a lot of work (grief ) and it looks like I can still just access the brushes without removing the armature ?
Thanks in advance...
You must remove the motor from the valve body, no way around it.
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Old 06-01-2016, 07:47 PM
Killa Meter Killa Meter is offline
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Re: Repair your own defective K1200GT ABS pump

Thanks looks like I've got a job to do might as well do it properly. If the motor is reassembled with bolts instead of peening, can it be removed from the pump next time while the pump and brake lines are still attached ?
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Old 06-01-2016, 08:09 PM
chopper_h chopper_h is offline
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Re: Repair your own defective K1200GT ABS pump

You don't state which K bike you have - on the R or S it is possible but requires loosening the mounting bolts and manhandling the body/pipes to create enough space to extract the motor.

On the GT, you have much more wriggle room.
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Old 06-01-2016, 11:00 PM
Killa Meter Killa Meter is offline
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Re: Repair your own defective K1200GT ABS pump

Sorry about that it's a 2007 R1200 GS.
Still would be easier if it was bolted least it would be easier to remove once you had the pump out. Thanks for the advice.
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  #114  
Old 06-02-2016, 12:00 AM
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Re: Repair your own defective K1200GT ABS pump

Quote:
Originally Posted by Killa Meter
Hey guys first post and sorry to resurrect an old thread but does anyone think I can remove the motor cover by removing the unit from the bike then drill the small holes to push the plastic tabs ,without removing the plate held on by the aluminium chiselled dimples, might save a lot of work (grief ) and it looks like I can still just access the brushes without removing the armature ?
Thanks in advance...

No idea what you mean by "aluminum chiselled dimples". But anyway, you have no choice but to remove the entire ABS unit with its motor. You also MUST remove the ball bearing at the end of the shaft to be able to remove the plastic brush plate. You CANNOT effectively free up the brushes while the brush plate is still attached!!!

But no matter what you do, the brushes are simply too "fat" to slide properly in their holders, so the REAL solution is to buy a used ABS unit from a 2012 Ford Fiesta (from Ebay ....less than $100) and use the brush plate assembly with brushes to replace yours. The Fiesta ABS brushes are slightl less "fat" and easily slide in their holders. Note that both ABS units are made by Continental-Teves. DO NOT simply swap the entire motor (even though they LOOK identical!) because the excentric at the end of the motor shaft (that drives the ABS pump internal pistons) is different on the Fiesta unit as compared with the BMW unit.

To reassemble the units, you CAN machine a custom motor mount that will allow you to screw the motor to the ABS body, as you can see how I did this.

Have a look at my comments and photos in these 3 threads. That show exactly how it is done.

http://www.i-bmw.com/showthread.php?...ght=ABS+repair

http://www.i-bmw.com/showthread.php?t=56223

http://www.i-bmw.com/showthread.php?t=55655
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- '08 K1200GT, metallic charcoal/silver
- '86 K100RT, Diamantgrau Metallic (great old girl!).
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Old 06-02-2016, 06:44 AM
Killa Meter Killa Meter is offline
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Re: Repair your own defective K1200GT ABS pump

Thanks , this site rocks you guys are awesome, love those custom motor mounts, decided right there and then this is what I will do, looks like a professional job done this way as well.
Thanks again
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  #116  
Old 06-02-2016, 11:42 AM
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Re: Repair your own defective K1200GT ABS pump

Glad to help out!
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No more "Vancouver.... the Blond Bimbo of Cities" for me
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- '86 K100RT, Diamantgrau Metallic (great old girl!).
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  #117  
Old 12-03-2016, 08:00 PM
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Re: Repair your own defective K1200GT ABS pump

I have a Bosch washing machine where the bushes used to get stuck. The method of giving them a gentle filing before placing them back in their guides fixed the problem for me.

That aside, has anyone tried a method that doesn't require disassembly such as ultrasonic vibrations or even just high frequency vibrations such as that you might get from a hammer drill? If the hammer drill method worked you might not even have to disconnect the unit, just free it's mounting a little so that the drills vibrations are not dampened by whatever the unit is mounted to. I'm not suggesting that someone try drilling into their unit with a hammer drill but rather something like having a rounded bar placed in the ðill chuck which is then placed against side of motor and perhaps encouraged to stay in one position by taping a washer or something that can stop the drill bit from sliding about. It must be worth a try.
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  #118  
Old 02-09-2017, 08:44 AM
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Re: Repair your own defective K1200GT ABS pump

I have a Fiesta ABS module on the way and am considering using the brushes or the whole motor to fix the ABS on my 2008 GS. I read that the Fiesta has 2mm of eccentricity compared to the BMW units 1mm, what difference will this make, is it likely to work the valves harder and cause premature wear in a different part of the unit or maybe cause excess pressure in the braking circuit?

Has anyone fitted the entire Fiesta motor and got any comments on the long term effects?

Also, why is the Fiesta unit better, if they both come from Teves will they not both have the same design issues?
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  #119  
Old 02-09-2017, 11:14 AM
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Re: Repair your own defective K1200GT ABS pump

I had used the entire motor for about 6 months without knowing that the eccentricity of the shaft was different. I had no problems, but thanks to the knowledge and informative postings of RFW, I have since fixed it properly with the original armature and Fiesta brush housing. It would be wise to fix it right rather than risk damage to the pump.
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  #120  
Old 02-10-2017, 06:58 AM
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Re: Repair your own defective K1200GT ABS pump

I guess you are right, its an expensive unit to break for the sake of an additional 30 minutes work. I am just being lazy and if I don't need to split the new motor then so much the better. New bearing ordered now so I will change the brush assembly over.

Thanks.
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