With the front calipers locking up after the key is switched on and the master cylinder refusing to move after a few strokes, I did a quick bleed of both the calipers and then disconnected the master cylinder to check its action. Confirming the fault lay in the ABS module I tore into the bowels of the bike to get at it.



On the earlier K1200RS with ABS II (non-servo) you must remove the rear wheel (no caliper removal required), the seat, plastic pannier mounts, both sidecovers, the battery & its stainless steel tray, the left hand passenger footpeg arrangement, the charcoal canister (if equipped - now where DID that thing get to when it's time to put it back on!?), and the forward inner part of the rear fender. It's all fairly straightforward - if not time-consuming - involving several different types of fasteners and BMW seem to have thought about access.



Once the pump is unscrewed, unplugged from the bike's loom, then lowered out the back and towards the ground, removing the plastic cover that says FTE (the manufacturer, it's not FAG or Bosch) to access the wiring to the module is a simple affair. Just tap gently and slide the cover up and off, exposing the 7 & 8mm nuts which hold the earth and power harness to the pump's electronic control.



One quick connect plug contains the rest of the wires, unscrew the two 11 & two 12mm hydraulic lines, catch the escaping brake fluid and you're free.



Module Master <(link) is where I'm sending it tomorrow. They've done a dozen or more for the two shops I've been affiliated with in Seattle and in Tacoma and they've not had one come back. They guarantee them for five years. With a new pump currently costing nearly US$2600 it's a good value for a refurb at $350. These modules also fit '94 through '98 K1100RS & K1100LT.

Edit: At the calipers were little spirals of rubber-like material in the brake fluid which came out when the banjo bolts were removed. The entire hydraulic system will be flushed, calipers, master cylinder, metal lines, and a Spiegler braided brake hose kit will replace the rubber bits.

Spiegler Brake hose kit

Sounds like some numptie used rtv silicone on the threads.

Possibly, the brake fluid was "the colour of a river but not nearly as brown*"...methinks it's rubber seals perishing or perhaps paint, like squishy little overcooked spiral pasta.

There were tiny paint dots on all of the brake joints, including the bleeders. I reckon no one ever flushed the fluid. I have a good stack of the service records and it ain't there.


*Homesick, listening to Paul Kelly
'Love never runs on time'

I've got a fully functional unit from a '99 K1100LT(80,000kms on the clock) sitting in the garage doing nothing if you're interested. $120. I've tried to sell it on fleabay with no interest before.

pm me if you're interested.

Al

I've just received the ABS module back from I-Da-Ho (Module Master) and it came back to me within a week, packed well, clean and tidy with a note suggesting the brake hoses be replaced as there was so much sh*te in the pump that the piston(s) were clogged up, causing the brake binding I was experiencing. The PO had no records to show the brake fluid had ever been changed! Itsa good thing I've got some spankin' new Spiegler hoses to go in, a six hose kit with silver banjo ends and smoke tint vinyl coverings over the braid. The calipers have been popped apart, cleaned out, new seals installed. My Monday off work will be the day to whack it all back together and with some luck hit the road for a shakedown run - I've yet to ride this bike I bought in January...


The yeller one

With just 20,753 original miles on the clock, I can't wait to hear that Remus Innovation's muted rumble behind me, test those new EBC brake pads slowing me and feel those Shinko Verge 02 tyres gripping the road beneath me. This bike will be for sale once it's proven to be in perfect nick. I need to clear the garage for something else.