04 Failed Brake Servo's - BMW Luxury Touring Community
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post #1 of 26 Old Nov 23rd, 2014, 4:47 pm Thread Starter
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04 Failed Brake Servo's

The servo brakes failed a couple of weeks ago on my 2004 LT when I was on the exit ramp going to work. I'm just going to bypass the ABS servo unit. I hope to have a Areoquip dealer in Charlotte make me 4 stainless braided brake lines to bypass the ABS unit & seal the lines from the ABS unit.

If everything works as planned I should have pictures in a few days. My goal is to not disturb any of the factory or Spiegler lines on my LT.

Dave Selvig
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post #2 of 26 Old Nov 23rd, 2014, 4:55 pm
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Re: 04 Failed Brake Servo's

You will need to pull the circuit card out of the ABS and hook it back up if you want a speedo, odometer, cruise control and brake lights.

John
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post #3 of 26 Old Nov 23rd, 2014, 5:03 pm Thread Starter
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Re: 04 Failed Brake Servo's

Explain a little more John. I'm not unhooking anything from the ABS unit but the brake lines to the calipers & I'm going to loop the lines from the ABS unit back to each other.

Dave Selvig
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post #4 of 26 Old Nov 23rd, 2014, 5:22 pm
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Re: 04 Failed Brake Servo's

Can you not just disconnect the wires for the two pressure pumps from the PC card, John had a pic on one of the threads of the pump motor driver chips, the board is probably better protected in the module

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post #5 of 26 Old Nov 24th, 2014, 5:36 am
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Re: 04 Failed Brake Servo's

Quote:
Originally Posted by saddleman View Post
The servo brakes failed a couple of weeks ago on my 2004 LT when I was on the exit ramp going to work. I'm just going to bypass the ABS servo unit. I hope to have a Areoquip dealer in Charlotte make me 4 stainless braided brake lines to bypass the ABS unit & seal the lines from the ABS unit.

If everything works as planned I should have pictures in a few days. My goal is to not disturb any of the factory or Spiegler lines on my LT.
Dave,

You might check with Module masters and see how far along they are with their fix on your module. They did my RT module and it works great with a 5 year warranty.

Motorcycle ABS Modules | Product Categories | ModuleMaster

Ron


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735,834 miles on touring motorcycles since 1990

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2003 LTE 164,188 miles Silver (Purchased with 1687)
2008 R1200RT 176,196 miles (Purchased with 16458)
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post #6 of 26 Old Nov 26th, 2014, 9:10 am Thread Starter
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Re: 04 Failed Brake Servo's

Everything is hooked up & all I have left to do is bleed the front & rear circuits.

I bought four 10 mm x 1.0 thread hex head bolts & shortened them to go into the unions with a washer to block off & seal the ABS lines. The brake fluid is still in the ABS unit & wont get contaminated. I had an extra front BMW union so I only had to buy the two rear unions. My total cost was $90 including the two custom made brake lines.
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post #7 of 26 Old Nov 26th, 2014, 10:10 am
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Re: 04 Failed Brake Servo's

Nice work Dave. I like the way you think. If mine ever goes it'll be a tough decision as to repair or just bypass. If I had the linked system, I believe I would do exactly what you have done. Be a little more careful on those corners now.........


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post #8 of 26 Old Nov 26th, 2014, 10:23 am
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Dave. How did you get your speedo and cruise to work. Also. Get the abs lights to go out?
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post #9 of 26 Old Nov 26th, 2014, 11:51 am Thread Starter
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Re: 04 Failed Brake Servo's

Quote:
Originally Posted by saddleman View Post
Everything is hooked up & all I have left to do is bleed the front & rear circuits.

I bought four 10 mm x 1.0 thread hex head bolts & shortened them to go into the unions with a washer to block off & seal the ABS lines. The brake fluid is still in the ABS unit & wont get contaminated. I had an extra front BMW union so I only had to buy the two rear unions. My total cost was $90 including the two custom made brake lines.
My 2000 LT that I ride in the mountains has manual brakes & the ABS unit has not been working for two years.

Dave Selvig
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post #10 of 26 Old Nov 26th, 2014, 11:54 am Thread Starter
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Re: 04 Failed Brake Servo's

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Dave. How did you get your speedo and cruise to work. Also. Get the abs lights to go out?
I never unhooked the ABS unit so the speedo & cruise should still work. I'll either remove the bulbs or unhook the relay to stop the blinking lights from working.

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post #11 of 26 Old Nov 26th, 2014, 11:59 am Thread Starter
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Re: 04 Failed Brake Servo's

I could have saved $16 if I had bought another 10 mm X 1.0 union & put the front lines together but I decided not to disturb any of the Speigler brake lines. the system has been bled now & no leaks.

Dave Selvig
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post #12 of 26 Old Nov 26th, 2014, 1:33 pm
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Re: 04 Failed Brake Servo's

Nice job Dave. Everything should work and pulling the warning relay will only kill one of the lights. The other one is driven from pin 9 (brown/red wire) on the ABS connector. or that matter pin 10 (brown/yellow) is the other one that drives the warning relay.

John
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But lack DE, MA, RI and CT with the 2005 LT

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post #13 of 26 Old Nov 26th, 2014, 1:42 pm Thread Starter
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Re: 04 Failed Brake Servo's

Thanks John I'll just remove the bulbs. If I did it again I would just join the front lines with a union. My set up doesn't fit to good between the air box & the tank. I had to lay a piece of rubber between the upper fitting & the tank.

Dave Selvig
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post #14 of 26 Old Nov 26th, 2014, 2:05 pm Thread Starter
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Re: 04 Failed Brake Servo's

I just turned the key on & you could here the servo's go through the self test. I applied the brakes after the servo's stopped & they worked for a few seconds & then quit just like they did the last few times I rode the bike. Also the last few days leading up to the servo's failing the rear brake would lock up at slow speeds.

This bike has always worn the rear brake pads & rotors at a much faster rate than what I consider normal. The rear rotor on it now was new 6 months ago from a triked bike & it is below min. spec. already.

Dave Selvig
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post #15 of 26 Old Nov 26th, 2014, 4:25 pm
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Re: 04 Failed Brake Servo's

Dave, there's an auto supply shop real close to here that makes custom brake hoses/lines while you wait. If interested, let me know and I'll put you together. A small family owned business, good work at reasonable prices.

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post #16 of 26 Old Nov 26th, 2014, 5:23 pm Thread Starter
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Re: 04 Failed Brake Servo's

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Dave, there's an auto supply shop real close to here that makes custom brake hoses/lines while you wait. If interested, let me know and I'll put you together. A small family owned business, good work at reasonable prices.
The next time your there Gunny see if they carry 3/16" vinyl braided steel brake line & 10 mm x 1.0 plus 12 mm x 1.0 thread crimp on fittings in straight, 45 & 90 degree.

Dave Selvig
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post #17 of 26 Old Nov 26th, 2014, 6:45 pm
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Re: 04 Failed Brake Servo's

How long did it take you?

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post #18 of 26 Old Nov 27th, 2014, 7:33 am Thread Starter
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Re: 04 Failed Brake Servo's

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How long did it take you?
I'm not sure Jim, I'm just working on it now & then this week and I have other maintenance I'm doing because this is this the first time I've done any work on it since I installed the clutch last year. I know it was 4 hours on Monday just rounding up parts.

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post #19 of 26 Old Nov 27th, 2014, 10:47 am Thread Starter
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Re: 04 Failed Brake Servo's

I changed the front lines this morning. I had an extra brake line union off of the rear lines & installed it. This fits much better.
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post #20 of 26 Old Nov 30th, 2014, 12:10 pm
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Re: 04 Failed Brake Servo's

Dave how is this set up still working for you reason I ask this is the route that I will be going if mine fails the only thing I think I would need a little more info when it comes to that point when I do that change but I will put it in my save documents THANKS AGAIN FOR SOME GREAT INFO.

Gary
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post #21 of 26 Old Nov 30th, 2014, 12:19 pm Thread Starter
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Re: 04 Failed Brake Servo's

I put some miles on it this morning & everything works fine. It stops just like my 2000 LT. On Wednesday morning I zip tied the hand brake lever & used a ratchet strap on the foot brake lever to hold them at about 80% down. I made sure I did not bottom out the master cylinders. After 24 hours I bled them for the last time & got a few more air bubbles out of each caliper.

The cruise & speedometer work just like they should. I also removed the light relay & the bulb so I have no flashing dash lights.
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post #22 of 26 Old Dec 14th, 2014, 5:38 pm
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Re: 04 Failed Brake Servo's

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The next time your there Gunny see if they carry 3/16" vinyl braided steel brake line & 10 mm x 1.0 plus 12 mm x 1.0 thread crimp on fittings in straight, 45 & 90 degree.
They tell me you can have them any way you want them. Also can have them in red, blue stainless or black.
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post #23 of 26 Old Dec 14th, 2014, 5:47 pm Thread Starter
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Re: 04 Failed Brake Servo's

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They tell me you can have them any way you want them. Also can have them in red, blue stainless or black.
Thank's, Gunny

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post #24 of 26 Old Oct 9th, 2015, 3:12 pm
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Cool Re: 04 Failed Brake Servo's

It seems I'll be going down this path at least temporarily.
If I understand correctly, were you to do it over again you would order a slightly different set of hoses. Would you please provide the specs of what you believe to be the best setup? I'll then give Gunny's shop my credit card and, hopefully, next weekend I'll be able to do the bypass.

Also of interest, has anyone here successfully replaced the iABS III with an ABS II modulator? I expect iABS II won't ever work with the ECU on a bike set up for iABS III. I apologize in advance if this notion has been bottomed out. I happen to own a modulator P/N 34 15 2 306 435.
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post #25 of 26 Old Oct 9th, 2015, 6:46 pm Thread Starter
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Re: 04 Failed Brake Servo's

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It seems I'll be going down this path at least temporarily.
If I understand correctly, were you to do it over again you would order a slightly different set of hoses. Would you please provide the specs of what you believe to be the best setup? I'll then give Gunny's shop my credit card and, hopefully, next weekend I'll be able to do the bypass.

Also of interest, has anyone here successfully replaced the iABS III with an ABS II modulator? I expect iABS II won't ever work with the ECU on a bike set up for iABS III. I apologize in advance if this notion has been bottomed out. I happen to own a modulator P/N 34 15 2 306 435.
The only hose I would have is the rear hose. I can't find the receipt to see how long it was.

Dave Selvig
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post #26 of 26 Old Oct 13th, 2015, 10:42 am
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Cool Re: 04 Failed Brake Servo's

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The only hose I would have is the rear hose. I can't find the receipt to see how long it was.
Thank you for checking.

Crumbs! I'll post details if I end up going this way. The bike stops well at this point and I remain hopeful a flush or a flush plus exercise will free up whatever is stuck.
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