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Enjoy The Ride
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Discussion Starter #1
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.
 

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Wrencher Extraordinaire
2005 K1200LT
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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.
 

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Enjoy The Ride
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Discussion Starter #3
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.
 

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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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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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Enjoy The Ride
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Discussion Starter #6
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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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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Dave. How did you get your speedo and cruise to work. Also. Get the abs lights to go out?
 

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Enjoy The Ride
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Discussion Starter #9
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.
 

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Enjoy The Ride
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Discussion Starter #10
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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Enjoy The Ride
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Discussion Starter #11
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.:D
 

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Wrencher Extraordinaire
2005 K1200LT
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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.
 

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Enjoy The Ride
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Discussion Starter #13
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.
 

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Enjoy The Ride
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Discussion Starter #14
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.
 

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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.
 

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Enjoy The Ride
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Discussion Starter #16
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.
 

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Enjoy The Ride
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Discussion Starter #18
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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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.
 
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