Integral ABS brakes diagram - BMW Luxury Touring Community
 
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post #1 of 21 Old Apr 7th, 2014, 8:34 am Thread Starter
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Integral ABS brakes diagram

Hello everybody,

Considering the many threads about the Integral brake system of the K1200 LT, and not wanting to be caught off my guard by a failure, I would be interessed to understand how it works.
Question has anyone a diagram or a technical description explaining the principles of this system and the fonctions of the different components.

Thank you

Bruno

Bruno_C
K1200 LT 2006 85000km
Moto Guzzi Breva 750 2004
Triumph Bonneville 1972
Norton Commando 1976

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post #2 of 21 Old Apr 7th, 2014, 11:11 am
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Re: Integral ABS brakes diagram

Bonjuor

Here is BMW's explanation of the system. The most important thing you can do is follow the brake fluid flush requirements. Annual on the wheel circuits and every two years on the control circuits. I have disassembled failed units and know pretty much what is going on inside.


These photos should give you an idea why the flush is so important.
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Attached Files
File Type: pdf Integral Brakes.pdf (75.6 KB, 886 views)

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #3 of 21 Old Apr 7th, 2014, 11:59 am Thread Starter
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Re: Integral ABS brakes diagram

Thank you Jzeiler

The attached document seems very interesting.
I am trying to get the figures to be able to understand.

Maybe you have them...

Thanks again

Bruno

Bruno_C
K1200 LT 2006 85000km
Moto Guzzi Breva 750 2004
Triumph Bonneville 1972
Norton Commando 1976

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post #4 of 21 Old Apr 7th, 2014, 1:34 pm
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Re: Integral ABS brakes diagram

+1 on Thanks for the article - I hadn't seen that before.

In the article it said: "You will find the figures mentioned in this article in the German issue of ATZ 3/01 beginning on page 200."

Jim
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post #5 of 21 Old Apr 7th, 2014, 11:09 pm
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Re: Integral ABS brakes diagram

I guess it has been a while since I have read that. Never did find the figures, maybe one of our German friends can help.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #6 of 21 Old Apr 8th, 2014, 12:47 am
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Re: Integral ABS brakes diagram

I too was wanting to see the full details a while back. I went to the "ATZ Worldwide" website, you need to pay to get the full article. As an aside, I have the factory test documentation for the pre-delivery braking system checks on my '05 (all in German). I might ask someone at my workplace to translate it. Plenty of people have asked why BMW have elected to use such an intricate iABS system, but when the tech article is digested you can see they have attempted to control the wheels to that critical point between locking and not being locked, unlike car ABS systems which actually lock and release the wheels, hence the complexity of the control system (and the braking modulator).

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post #7 of 21 Old Apr 8th, 2014, 6:27 am Thread Starter
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Re: Integral ABS brakes diagram

I have the factory test documentation for the pre-delivery braking system checks on my '05 (all in German).

K100 DENIS,

Could you please copy this documentation.
Even in german, it could help to understand how it works.

Thank you

Bruno

Bruno_C
K1200 LT 2006 85000km
Moto Guzzi Breva 750 2004
Triumph Bonneville 1972
Norton Commando 1976

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post #8 of 21 Old Apr 8th, 2014, 4:57 pm
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Re: Integral ABS brakes diagram

Please see attached pdf of the FTE Integral Brake System test and bleed procedure prior to delivery of the bike.
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File Type: pdf FTE iABS data.pdf (25.3 KB, 502 views)

Dennis
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post #9 of 21 Old Apr 9th, 2014, 11:45 pm
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by jzeiler View Post
. I have disassembled failed units and know pretty much what is going on inside.
So,
If a failed unit is removed and repaired (or replaced)
Is it possible for a mear mortal to bleed the entire system and get the brake system working properly?
or is a visit to the dealer necessary?

I thought one of the important things was to NEVER get air in the unit... or a special tool/procedure etc. would be necessary...

ps
thanks for the reply on my other post/thread.

True Wisdom Only Comes From Pain.


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post #10 of 21 Old Apr 10th, 2014, 9:49 am
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Re: Integral ABS brakes diagram

Very interesting read. I am even more impressed with its capabilities. It is a shame they system could not be maintained without all those expensive flushes for us non mechanics. I guess our safety is worth it ?????
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post #11 of 21 Old Apr 10th, 2014, 9:54 am
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by andres View Post
For fear of contravening copyright provisions I do not feel comfortable posting the article on this forum. I sent you a PM.
You gotta be kidding me.

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post #12 of 21 Old Apr 10th, 2014, 2:28 pm
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by johnT View Post
So,
If a failed unit is removed and repaired (or replaced)
Is it possible for a mear mortal to bleed the entire system and get the brake system working properly?
or is a visit to the dealer necessary?

I thought one of the important things was to NEVER get air in the unit... or a special tool/procedure etc. would be necessary...

ps
thanks for the reply on my other post/thread.
Yes it is not rocket science to bleed the system, a flush is much easier and that is when you don't want to allow air in. Any time a component is replaced, caliper, hose, etc. you must perform a bleed of that circuit. The only thing you cannot do that the dealer can is run the bleed test with the computer. But now you can do that with the GS-911 units.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #13 of 21 Old Apr 10th, 2014, 3:09 pm
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by jzeiler View Post
. But now you can do that with the GS-911 units.
OK, Gotcha..

I'm going to remove the unit this weekend and take it apart to see if I can find anything obvious.... honestly, I think it's probably gunked up from going 80K miles without a control flush. (let this be a lesson boys and girls)

But anyway, If it still don't work I'm gonna yank the entire thing... and run traditional lines from master cyl. to calipers

I will unbolt the electrical box/plug and retain it... like you mentioned in a few other threads...

I'm sure you see me sniffin around...

True Wisdom Only Comes From Pain.


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post #14 of 21 Old Apr 10th, 2014, 5:59 pm
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Re: Integral ABS brakes diagram

John,

Just pull the output ports where the outgoing lines were. They have a long fine filter on them and that will give you an idea of the internal condition.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #15 of 21 Old Apr 10th, 2014, 11:17 pm
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by jzeiler View Post
John,

Just pull the output ports where the outgoing lines were. They have a long fine filter on them and that will give you an idea of the internal condition.


True Wisdom Only Comes From Pain.


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post #16 of 21 Old Apr 12th, 2014, 1:23 pm
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Re: Integral ABS brakes diagram

Found a burned section in the circuit board...
any idea if this burned section controls the servo to the front or both?

I am thinking that was the problem... the screens for the input and output looked fine.
however the brake fluid looked like a fine Colombian coffee..


Anyway, I decided to remove the entire system. The brakes in the front feel great when I was done..
That is, until the right side rubber hose ruptured..
so, I will be ordering SS lines for both front and back.

They are the stock lines (2002) so It's about time to replace them anyway... actually glad it broke now and not in east bumphuck...

concerning the burned section on the board, My brake lights and speedo were working previous... so I think I will be OK plugging it back in.


burned section is top left hand corner.... click on it to enlarge pic.
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post #17 of 21 Old Apr 12th, 2014, 2:39 pm
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Re: Integral ABS brakes diagram

That would be the driver chip for the Front circuit pump. I had a board with some of those but I had sent it to a guy in Holland to fix his unit. Most likely cause was crud in the pump that stalled the motor and burned out the chip.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #18 of 21 Old Apr 13th, 2014, 7:28 am
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by jzeiler View Post
. Most likely cause was crud in the pump that stalled the motor and burned out the chip.
Yep,

I took apart the abs/servo assist control unit.. and that side (front) was very dirty.... also the motor on that side was dead... I reckon when the pump was getting tight it took out the motor and the chip.....

the other motor spins fine with 12v

Oh well... it's all in the garbage can now... waiting for my Galfer SS lines.

thanks for the help (again)

and sorry Bruno for hijacking your thread....

True Wisdom Only Comes From Pain.


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post #19 of 21 Old Apr 13th, 2014, 8:56 am
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by johnT View Post
Yep,

I took apart the abs/servo assist control unit.. and that side (front) was very dirty.... also the motor on that side was dead... I reckon when the pump was getting tight it took out the motor and the chip.....

the other motor spins fine with 12v

Oh well... it's all in the garbage can now... waiting for my Galfer SS lines.

thanks for the help (again)

and sorry Bruno for hijacking your thread....
Sounds like it could be a source of spares for John Z...

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post #20 of 21 Old Apr 13th, 2014, 12:22 pm
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by Voyager View Post
Sounds like it could be a source of spares for John Z...
Way ahead of me. Just sent John a PM.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

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post #21 of 21 Old Apr 13th, 2014, 12:41 pm
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Re: Integral ABS brakes diagram

Quote:
Originally Posted by jzeiler View Post
Way ahead of me. Just sent John a PM.
replied.

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