2004 RT brake failure / Repair?

[willyb]

I have a 2004 R1150RT with 32,000 miles on it, Late last fall on a 3 day trip my brake failure light appeared and the servo was working off and on being not far from a BMW dealer at the time I limped it in and after a short time they diagnosed the problem being the ABS servo had failed. My son was kind enough to rescue me and drove 250 miles to trailer the bike home. Home being Minnesota I figured I would deal with it over the winter. Now spending $2,300.00 for a new module for a $4,000.00 dollar bike makes no sense to me so next up is Module Masters for a rebuild for about $700.00 with a five year warranty, they just tarted rebuilding these units and I have been on a waiting list all winter. I pulled the unit last week and was told they are still working through their waiting list. So now I'm thinking maybe just delete the unit and run with standard brakes and no ABS, after some research there are different ways to go about this. I guess I am looking for advice and input from the group on the delete procedure.

[dirtrider]

8 hours ago, willyb said:

I have a 2004 R1150RT with 32,000 miles on it, Late last fall on a 3 day trip my brake failure light appeared and the servo was working off and on being not far from a BMW dealer at the time I limped it in and after a short time they diagnosed the problem being the ABS servo had failed. My son was kind enough to rescue me and drove 250 miles to trailer the bike home. Home being Minnesota I figured I would deal with it over the winter. Now spending $2,300.00 for a new module for a $4,000.00 dollar bike makes no sense to me so next up is Module Masters for a rebuild for about $700.00 with a five year warranty, they just tarted rebuilding these units and I have been on a waiting list all winter. I pulled the unit last week and was told they are still working through their waiting list. So now I'm thinking maybe just delete the unit and run with standard brakes and no ABS, after some research there are different ways to go about this. I guess I am looking for advice and input from the group on the delete procedure.

 

 

Morning Willyb

 

There are a few ways to do the ABS module removal.  (your present brake switches operate backwards to the way  you need them to operate after ABS removal).

 

The easiest way is to keep your existing brake switches then use the ABS warning light relay (plus some wiring changes) to  reverse brake switch input (ie allow present brake switches to correctly operate brake lights). You can do all the wiring/relay addition right at the existing ABS module connector area.

 

Then either make (or have made) the necessary brake lines, or install new brake hoses. 

 

Some do the brake lines in different ways. Some use a longer rear brake hose direct from master cylinder to rear caliper, (personally) I use the existing rear  parts then make up a new (shorter) metal brake line from master cylinder to existing rear brake hose (more difficult to do but makes a cleaner installation).

 

On the front brake hoses/lines, you can use the original parts if you are creative.  

 

I think  (  AndyS  ) did a write up on the 1150RT ABS removal so you might PM him to see if he will PM you back his procedure.  

[willyb]

Thanks dirtrider for the reply a google search turned up a few procedures, I just thought someone on the forum would be able to steer me to the easiest And best way forward. Also wondering if some one makes a kit for this conversion.

 

[dirtrider]

58 minutes ago, willyb said:

Thanks dirtrider for the reply a google search turned up a few procedures, I just thought someone on the forum would be able to steer me to the easiest And best way forward. Also wondering if some one makes a kit for this conversion.

 

 

Afternoon Willyb

 

As far as a dedicated  kit goes, that might be difficult to find as very few suppliers would make, or  even word,  a kit as "for removing a braking safety feature"   due to possible liability concerns. 

 

You really don't need much in the line of hydraulic parts as it is mostly just a new longer rear brake hose or having a shorter rear metal brake line made up. On the front you can repurpose the existing hose & reposition the Tee.

 

The electrics part is something that you will have to make (or have made) but it is JUST a relay (you can use your existing ABS warning relay then adding a socket for the relay (or even just wires with terminals to the relay).

 

All, the wires that you need to work with are right at the same removed ABS controller connector.

 

The front & rear brake switch wires are combined then used to operate the relay with the existing  B+ at the connector going through the relay to turn the brake lights on. (even a caveman can do it)

 

I can do a  wire schematic on the conversion but you might  first try contacting  AndyS  by PM as I'm pretty sure he did an easy to follow write up on the conversion (It should also be in the archives here (IF) you can find it).  

 

I do mine a little different as I am a stickler for OEM packaging  & neat looking wire harnesses ,  plus I like easy future troubleshooting, but it is mostly in the use of a steel rear line & wiring connections that are closer to factory (I have access to difficult to find terminals & connectors so usually don' t like to cut factory wring if at all possible).      

[willyb]

Thanks again dirt, I will see if I can locate Andy's post or contact him.

 

[willyb]

Also I just installed new SS brake lines last year, Hoping to retain these.

[dirtrider]

24 minutes ago, willyb said:

Also I just installed new SS brake lines last year, Hoping to retain these.

 

Afternoon Willyb

 

Then you probably want to go with the shorter  rear metal line option.