BMWSportTouring

2003 r1100s ABS failure 2x in 4K miles

Posted By: oilhead1100s1150rt

2003 r1100s ABS failure 2x in 4K miles - 11/07/17 11:50 PM

Good Day, I have lost a second ABS pump in 4K miles, over 6 years. Dealer wants 3500 to replace. Is it difficult to just get rid of ABS all together? I am told I will not pass PA inspection without ABS as the bike was built with iABS. Very disappointed and struggling with my next step. ABS lights read low level in ABS unit. Dealer says fault readout points to bad pump.

Thoughts? Anyone else have failures this close together?

Thanks...
Posted By: dirtrider

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/08/17 12:11 AM

Originally Posted by oilhead1100s1150rt
Good Day, I have lost a second ABS pump in 4K miles, over 6 years. Dealer wants 3500 to replace. Is it difficult to just get rid of ABS all together? I am told I will not pass PA inspection without ABS as the bike was built with iABS. Very disappointed and struggling with my next step. ABS lights read low level in ABS unit. Dealer says fault readout points to bad pump.

Thoughts? Anyone else have failures this close together?

Thanks...


Evening oilhead1100s1150rt

Well, you can remove the ABS system but you will probably lose your speedometer unless you can find a way to retain the current ABS electronics & mask the failure light & relay. (it can be done just not easily).

As far as passing the state test without an active ABS system-- that depends on IF they know that you removed the ABS system, or IF they actually run a rolling road ABS operational test.

They did build the 1100s without an ABS system so unless they look at the vehicle factory build sheet or are a very knowledgeable in BMW motorcycle equipment & model build equipment I doubt they will know that it came with factory ABS.
Posted By: oilhead1100s1150rt

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/08/17 12:18 AM

Thanks DR, does not sound like a good idea and may cause additional issues once removed. There most be a rebuild shop or refurbished outlet some place. There have been many of these failures on iABS. I have searched, but will need to dig even deeper. $3500 a few years ago for my first replacement, now additional $3500, is getting to be too much. My biggest worry is in a few more years, I get ti again. Bike runs very well motor/tranny wise.
Posted By: dirtrider

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/08/17 12:24 AM

Originally Posted by oilhead1100s1150rt
Thanks DR, does not sound like a good idea and may cause additional issues once removed. There most be a rebuild shop or refurbished outlet some place. There have been many of these failures on iABS. I have searched, but will need to dig even deeper. $3500 a few years ago for my first replacement, now additional $3500, is getting to be too much. My biggest worry is in a few more years, I get ti again. Bike runs very well motor/tranny wise.




Evening oilhead1100s1150rt

Probably the smart move is to POSITIVLY identify the failure then access it's repair potential.

If you can identify the failure you can then call Module Masters & see if they can repair that type I-ABS failure.

Do your servo pumps work or are they dead?
Posted By: oilhead1100s1150rt

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/08/17 12:57 AM

DR, the pumps seem to work at this point. They do have an audible, and stopping power appears to be fine. Just the flashing lights saying low fluid. I did call Module Masters, they told me they would have a pump available around Jan 2018 for the iABS module. I understand through various searches, that they have had several delays in their release time for this module. I am thinking it might be worth the wait at this point, they quoted me around $800 - $900 which is 1/3 the price of a new one from BMW. I also have an ABS failure on my 2002 r1150rt. The lights on that bike (same iABS unit) read one circuit in residual mode. This bike slowly did fail. Braking slowly quite and eventually there is just residual mode now. Tech told me that the pump would come on when the key was turned in the ignition. Again, dealership is saying bad pump. So two bikes, two complete pump failures. I am thinking I should be able to get the readouts from the dealership??
Posted By: dirtrider

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/08/17 11:29 AM

Originally Posted by oilhead1100s1150rt
DR, the pumps seem to work at this point. They do have an audible, and stopping power appears to be fine. Just the flashing lights saying low fluid. I did call Module Masters, they told me they would have a pump available around Jan 2018 for the iABS module. I understand through various searches, that they have had several delays in their release time for this module. I am thinking it might be worth the wait at this point, they quoted me around $800 - $900 which is 1/3 the price of a new one from BMW. I also have an ABS failure on my 2002 r1150rt. The lights on that bike (same iABS unit) read one circuit in residual mode. This bike slowly did fail. Braking slowly quite and eventually there is just residual mode now. Tech told me that the pump would come on when the key was turned in the ignition. Again, dealership is saying bad pump. So two bikes, two complete pump failures. I am thinking I should be able to get the readouts from the dealership??


Morning oilhead1100s1150rt

Yes, try to get the failure code read out if possible (that can make the troubleshooting much easier).

Please keep your failure condition to JUST this bike as quoting 2 different bike failures will make it so much more difficult to keep track of what system is doing what.

With your pumps appearing to work that usually says the internal pressure sensors are working (the difficult thing for Module Masters to repair).

So lets get back to this bike -- tell us again EXACTLY what this bike's brakes are doing, when they are doing it, what the dash lights are doing, ANYTHING else for THIS BIKE.

If both pumps are working then it might be something simple that can be repaired at home.
Posted By: oilhead1100s1150rt

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/09/17 03:22 PM

2003 r1100sa - Lights read out = low fluid in abs module - per various online service manuals, and shop manual. Brakes feel like they are working individually, front and back both have firm stopping power, with normal pressure applied, from what I can tell. Will be picking up bike early next week, get fault codes, and will re-engage this post then. Will post a separate thread for secondary bike, good point DR, thanks. Stand-bye...
Posted By: Alan Sykes

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/09/17 03:24 PM

Sorry guys, if you read all the various BMW Oilhead forums, not just this one, you'd know that iABS removal is not at all difficult to do and many, many riders all over the world have done it, most reporting greatly improved braking performance, once the 13kg lump has been ditched.

It was a stoopid idea in the first place by BMW to have linked ABS with a servo whine annoying you every time you touch the lever or pedal and the firm moved on from it in pretty short measure.

However, there's no denying that a 2-wheeler equipped with an efficient modern ABS system, as for example in Honda bikes, is a much safer vehicle to crash-stop than a bike without ABS.

Nichtsdestoweniger, as Frau Quandt would say, the iABS is a pesky fault-prone system and is impossibly expensive to replace on a ten-year-old vehicle. It just doesn't make sense, despite the sterling efforts at refurbishment by firms like RHelektronik.de in the Fatherland, who service, repair and even replace these pesky FHF units every day of the year.

Just go on the web, look for ABS-ectomy or something, and follow the lead of the various videos. Just don't be tempted to cut any wires, as the excellent Chris Harris first did and found he then had no speedo nor brake lights. He was obliged to upload a short correction sequence.

But as I say, rest assured folks, it CAN be done without too much hassle. Even the esteemed MW in Meltham Bridge, Yokkshurr, Blighty, sell the various linking pipe / union bits to bypass the entire gold-durned system.
As for the annual tech-test roadworthiness check, worry not. They just test how good the bike is at stopping. They don't look at the factory-amalgamation data, whichever country you're in, do they ?
ALAN in s.e. Spain
Posted By: dirtrider

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/09/17 03:31 PM

Originally Posted by Alan Sykes
Sorry guys, if you read all the various BMW Oilhead forums, not just this one, you'd know that iABS removal is not at all difficult to do and many, many riders all over the world have done it, most reporting greatly improved braking performance, once the 13kg lump has been ditched.

It was a stoopid idea in the first place by BMW to have linked ABS with a servo whine annoying you every time you touch the lever or pedal and the firm moved on from it in pretty short measure.

However, there's no denying that a 2-wheeler equipped with an efficient modern ABS system, as for example in Honda bikes, is a much safer vehicle to crash-stop than a bike without ABS.

Nichtsdestoweniger, as Frau Quandt would say, the iABS is a pesky fault-prone system and is impossibly expensive to replace on a ten-year-old vehicle. It just doesn't make sense, despite the sterling efforts at refurbishment by firms like RHelektronik.de in the Fatherland, who service, repair and even replace these pesky FHF units every day of the year.

Just go on the web, look for ABS-ectomy or something, and follow the lead of the various videos. Just don't be tempted to cut any wires, as the excellent Chris Harris first did and found he then had no speedo nor brake lights. He was obliged to upload a short correction sequence.

But as I say, rest assured folks, it CAN be done without too much hassle . Even the esteemed MW in Meltham Bridge, Yokkshurr, Blighty, sell the various linking pipe / union bits to bypass the entire gold-durned system.
As for the annual tech-test roadworthiness check, worry not. They just test how good the bike is at stopping. They don't look at the factory-amalgamation data, whichever country you're in, do they ?
ALAN in s.e. Spain


Morning Alan

So how do you get a working speedometer without much hassle?
Posted By: oilhead1100s1150rt

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/09/17 08:21 PM

FYI.... Module Masters just told me "check back in a few months".....they are testing the final component .......iABS.
Posted By: dirtrider

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/09/17 08:28 PM

Originally Posted by oilhead1100s1150rt
FYI.... Module Masters just told me "check back in a few months".....they are testing the final component .......iABS.


Afternoon oilhead1100s1150rt

Did you tell Module Masters that you think the servo pumps are operating?

The big hang-up in repairing the BMW I-ABS controller is the internal pressure sensors (they are/were not available) so IF your pumps are working then it doesn't sound like you have a pressure sensor issue.

It might be worth another call to Module Masters & having an in-depth talk with them as they might be able to repair your unit now.
Posted By: 041100S

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/09/17 10:41 PM

Have an 04 R1100S ABS and am always concerned about this failure, so flush system every year. Have always found threads about removing ABS system that says the electronics can be separated from the pump to keep speedometer and brake light working, so possible to remove. Also, though I found this website, the company is in Germany, but maybe an option, but know nothing about the company, here is a link, https://rhelectronics.de/.
Posted By: AndyS

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/10/17 09:32 AM

Originally Posted by oilhead1100s1150rt
FYI.... Module Masters just told me "check back in a few months".....they are testing the final component .......iABS.

Don't hold your breath on this. For the 1150RT, they have been saying this since at least 2006 ish. I can't see them warranting the time to look into doing this for the limited number of bikes that will be left running. Most folk have ripped their Servo unit out and tossed it in the bin. It may well be different for the R1100S though.Me? Suspiciosly doubtful. However, as DR mentions, because it is the ABS element of the unit, they may be able to do something.
Posted By: ct11s

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/13/17 01:55 AM

Hi, new to this forum. I've done two iABS removals (both on '04 R11s) due to failure and it is not hard. My first experience with iABS failure was while riding and that was NOT something I want to experience again. The electronic module can be detached from the pump (4 screws) leaving the wiring connection from the harness in place - this retains the speedo function. I used aluminum sheet from a hardware store to fashion a cover for the exposed part of the electronic module. Ditch the pump and associated hard lines and replace the old rubber lines with braided ones (I used Spiegler). For the front, I ran dual lines from the master to each caliper. The ABS light will remain on so I removed the light from the instrument cluster.
Posted By: Alan Sykes

Re: 2003 r1100s ABS failure 2x in 4K miles - 11/18/17 11:48 AM

Hi to 041100S in Ark.
Lovely silver-looking bike you have.
Regarding the German firm RHelectronics, I know a couple of UK riders who were happy with their 800+ euro investment in having their iABS box repaired by that firm, instead of just ripping the entire system out.
Expensive, but if you so value the facility of the iABS, cheaper than a new module I suppose.
Posted By: oilhead1100s1150rt

Re: 2003 r1100s ABS failure 2x in 4K miles - 02/01/18 01:25 AM

After taking the bike to the dealer for a state inspection, failed. Tested iABS and told me servo unit needs replacement. I have copies of the test reports. I took the bike back, not paying them what they asked to repair. I then contacted Tom C at Rubber Chicken Racing for some assistance on this back in November. His work schedule was backed up to the point he was not taking any more new work. Put me in the "work to do file". I have not heard back from him yet. I will give him a call later this week in hope I can get him to take a look. Will be digging back into this shortly, as now my second bike has also failed iABS (2002 1150rt).
Posted By: kioolt

Re: 2003 r1100s ABS failure 2x in 4K miles - 02/01/18 01:43 AM

I quickly read through all of your posts on this and did not see anywhere where you said you checked the level of the fluid in the abs servo under the tank. That's what the low level error means. Before I would pay a dime I would check that . It doesn't cost anything for you to do it yourself. As far as I know the ABS servo will not give a low level error message for the master cylinders. It will probably give some other message for that. Pull the tank and check.
Posted By: oilhead1100s1150rt

Re: 2003 r1100s ABS failure 2x in 4K miles - 02/01/18 05:40 PM

Thanks kioot, I have not done so, correct. I have taken the feedback from the dealership. I asked directly if the fluid was low, as I understood the readout to say, and the response was failure. I know, I know, probably not a good idea. As soon as I get a day above freezing, I will do it myself as suggested. Good point, thanks!
Posted By: oilhead1100s1150rt

Re: 2003 r1100s ABS failure 2x in 4K miles - 02/01/18 06:07 PM

Additional details from Integrated Service Technical Application (BMW Tool) - readout from dealership

Identification Mode:

Fault description - measured wheel brake pressure at the front wheel is too high in relation to the control pressure.
Condition for fault ID - Voltage supply 9.0 V < U < 16.0 V Term 15 on
Fault Mem condition - Wheel brake cylinder pressure too high in relationship to control pressure
Action in service - Check break light with, hand, adjust break lights switch hand, check front pressure, check deviation values of internal sensors
check control unit
Note on effect - Brake servo assist front deactiveted, ABS control front deactivated
Fault description - break level too low
condition for fault memory - Brake level fluid detected too low for more than 8 secs
Action in service - check level in wheel circuits, check break fluid sensor and cables

Diagnostic Mode:
1st report -
Break Fluid Level - faulty
Break light switch - front and rear not operating
pressure - master rear = 22.38, master front 22.76 bar, wheel cyl rear = 21.79, wheel cal front = 66.07
control valve front and rear not active
Operating hours counter - front 3:15:00, fear 2:56:32
Battery voltage 12.05
Break light switch front = 2.75, rear = 2.75
Speed Sensor rear = 1.46, front = 1.56
Control valve front not active,rer not active
ABS control time front = 00:00:02, rear = 00:00:04
Operating Hours control unit = 64:50:42
Breaking time front = 3:15:00, rear = 2:56:32

I have readouts on my second bike(r1150rt 2002), but it looks like the test was unable to be done, will post separately.
Posted By: dirtrider

Re: 2003 r1100s ABS failure 2x in 4K miles - 02/01/18 07:14 PM

Afternoon oilhead1100s1150rt

Additional details from Integrated Service Technical Application (BMW Tool) - readout from dealership

Identification Mode:

Fault description - measured wheel brake pressure at the front wheel is too high in relation to the control pressure.--This could be pointing to a failed or failing internal pressure sensor (somewhat common I-ABS failure point).

Condition for fault ID - Voltage supply 9.0 V < U < 16.0 V Term 15 on

Fault Mem condition - Wheel brake cylinder pressure too high in relationship to control pressure-- Could be pointing to an internal pressure sensor issue as it would be difficult to get wheel side pressure too high without also having high control side pressure.

Action in service - Check break light with, hand, adjust break lights switch hand, check front pressure, check deviation values of internal sensors
check control unit

Note on effect - Brake servo assist front deactiveted, ABS control front deactivated
Fault description - break level too low
condition for fault memory - Brake level fluid detected too low for more than 8 secs
Action in service - check level in wheel circuits, check break fluid sensor and cables
--This usually points to either a low wheel circuit reservoir being low or a failing reservoir level sensor.

Diagnostic Mode:
1st report -
Break Fluid Level - faulty
Break light switch - front and rear not operating-- might be due to starting engine with foot on the brake pedal or holding in front brake lever during engine starting.
pressure - master rear = 22.38, master front 22.76 bar, wheel cyl rear = 21.79, wheel cal front = 66.07
control valve front and rear not active
Operating hours counter - front 3:15:00, fear 2:56:32
Battery voltage 12.05
Break light switch front = 2.75, rear = 2.75
Speed Sensor rear = 1.46, front = 1.56
Control valve front not active,rer not active
ABS control time front = 00:00:02, rear = 00:00:04
Operating Hours control unit = 64:50:42
Breaking time front = 3:15:00, rear = 2:56:32

I have readouts on my second bike(r1150rt 2002), but it looks like the test was unable to be done, will post separately.


On this problem I would check both under fuel tank ABS controller reservoir fluid levels & if OK then check the integrity & continuity of both reservoir level sensors (probably not the issue but could be so is the place to start)

It is sort of pointing to failed or failing internal pressure sensor or sensors but verify the above first.
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