The K1200RS ABS Chronicles
Where to start? I’ve owned my ‘02 K1200RS since new. Per its VIN, it has a fall ‘01 build date. I’ve mostly done the maintenance by myself, and the bike runs great now with about 60,000 miles (or just shy of 100,000 KM). I’ve had no mechanical problems with the bike and it is equipped with heated grips, cruise control, and the dreaded iABS or servo assist ABS system.
One thing that I’ve always paid attention to is the brakes, flushing and changing out the brake fluid annually and long ago swapping out the stock, known to fail, brake lines, with stainless steel lines from Spiegler (sourced from the excellent www.pirateslair.net.) I have the necessary special tools necessary to access, open and close, four of the six bleed ports on the ABS unit, along with a very useful funnel from www.beemerboneyard.com that makes avoiding emptying the rear fluid reservoirs during the brake flush / bleed process more straightforward.
About two years ago, I was about the head off on a weekend ride, when I noticed the dreaded “brake failure” light staying on after the normal start up process, the rear servo motor on the ABS unit was not functioning. The front brakes functioned as ever, the rear brakes had no power assist. Oh oh, the dreaded ABS pump failure. I went on the ride anyway, I mostly rely on the front brakes anyway, and reminded myself to exercise more caution than usual. Arrived at my friends house, some 220 miles north of me (I live in Los Angeles,) without incident.
The next morning he and I were going to ride to Carmel Valley for the Quail Lodge Concours, about 100 miles further up the road. Surprisingly, the brakes went through their normal check, and the rear servo came back to life, and the brakes functioned normally. Phew, dodged a bullet.
For the next 18 months or so, the brakes worked as expected, until this winter (we are fortunate to ride year round in California) when the rear servo failed, and only the front brake servo was working.
Time to do something about it. I figured I had 4 options, sell the bike as is, look into an ABS bypass set up, get the unit repaired, or buy a new unit from the dealer. Well guess what? A new unit presents a typical Catch 22. The cost of the unit from a dealer is about $3,500 USD, but, BMW no longer sells the unit, even if you’re willing to spend $3,500 on a bike that is not worth that much.
I like the bike, and once in all the years, the ABS brakes saved my ass, so, I chose the repair approach. To my knowledge there is only one place in the world where there is a shop that will repair the servo iABS system BMW offered from 2001 (in Europe) 2002-2007 in the rest of the world, that is RH Electronics ( www.rhelectronics.de ) in Hattenhofen Germany. I may be wrong about this, but it’s the only shop I could find.
I filled out a request for service form online, received an email, stating that the repair would be estimated at 990 Euros, independent of shipping (the English / German communication was a slight hurdle but doable.) I am a reasonably competent parts changer, so I tackled removing the ABS unit. It is a pain. I also learned the BMW used 2 8mm Torx bolts, not Allen head type Torx fasteners, but Torx bolts. These two bolts are used to secure the ABS unit into it’s holder, and are difficult to access, and impossible to remove without the proper wrench. Not having Torx open end, or box wrenches, I found some on line and ordered a set of open end / box wrenches, and sockets. Add about $50 for tools that I may use this one time only, but you can never have too many tools, right?
So with only non-fatal bloodshed, an assortment of language that would make a sailor proud, and more than a beer or two, I was able to remove the ABS unit, and pack it up for shipping. RH warned to pack it securely as damage in shipping was not unknown. Took the unit down to my local UPS store, and with tariffs and everything it cost about $330 to ship to Germany. I was tracking the unit, and UPS Germany was having a hard time locating the shop, but a few email exchanges with RH, they were able to contact UPS and have the unit delivered, but instead of a week or so for shipping, it took close to three. AND THEN, RH sent photos of the box and the unit, and it looked like UPS backed a truck over it. I made a claim on UPS, they’ve not acted on it, so, being an attorney, I’ve sued - in small claims court. More fun.
In any event, RH said they could repair it for an extra $330 Euros. Instead of taking about 2 weeks to turn the unit around, it took about 2 months. In any event, the unit has been returned, with new parts, and looking shiny and usable - one hopes.
Next, the re-installation, filling the system with brake fluid, and bleeding.
Well, a few more curses, a few more bloody knuckles, and the unit has been installed. Next I bled the brake system, and much to my delight, the brake went through it’s self check, and now functions as if new.
Was it worth it, I like the bike, and it probably cost about $1,750 dollars to have the unit repaired. I dread to think what I would have had to pay a mechanic to do the work, even if I could find one that would be willing, with shop rates what they are these days. The choice was mine, not many of us hold onto a bike as long as I’ve had this one (but then I have a 1978 Ducati 900SS too). It certainly was cheaper than going out and buying a new bike, or a newer used bike. Would I do it again? Hopefully I won’t have to face that decision in the future, but I do recommend RH in Germany should you be considering it.
The first photo is the unit on the bench before shipping, the rest are the box as received in Germany, and the damage to the unit in the box.
One thing that I’ve always paid attention to is the brakes, flushing and changing out the brake fluid annually and long ago swapping out the stock, known to fail, brake lines, with stainless steel lines from Spiegler (sourced from the excellent www.pirateslair.net.) I have the necessary special tools necessary to access, open and close, four of the six bleed ports on the ABS unit, along with a very useful funnel from www.beemerboneyard.com that makes avoiding emptying the rear fluid reservoirs during the brake flush / bleed process more straightforward.
About two years ago, I was about the head off on a weekend ride, when I noticed the dreaded “brake failure” light staying on after the normal start up process, the rear servo motor on the ABS unit was not functioning. The front brakes functioned as ever, the rear brakes had no power assist. Oh oh, the dreaded ABS pump failure. I went on the ride anyway, I mostly rely on the front brakes anyway, and reminded myself to exercise more caution than usual. Arrived at my friends house, some 220 miles north of me (I live in Los Angeles,) without incident.
The next morning he and I were going to ride to Carmel Valley for the Quail Lodge Concours, about 100 miles further up the road. Surprisingly, the brakes went through their normal check, and the rear servo came back to life, and the brakes functioned normally. Phew, dodged a bullet.
For the next 18 months or so, the brakes worked as expected, until this winter (we are fortunate to ride year round in California) when the rear servo failed, and only the front brake servo was working.
Time to do something about it. I figured I had 4 options, sell the bike as is, look into an ABS bypass set up, get the unit repaired, or buy a new unit from the dealer. Well guess what? A new unit presents a typical Catch 22. The cost of the unit from a dealer is about $3,500 USD, but, BMW no longer sells the unit, even if you’re willing to spend $3,500 on a bike that is not worth that much.
I like the bike, and once in all the years, the ABS brakes saved my ass, so, I chose the repair approach. To my knowledge there is only one place in the world where there is a shop that will repair the servo iABS system BMW offered from 2001 (in Europe) 2002-2007 in the rest of the world, that is RH Electronics ( www.rhelectronics.de ) in Hattenhofen Germany. I may be wrong about this, but it’s the only shop I could find.
I filled out a request for service form online, received an email, stating that the repair would be estimated at 990 Euros, independent of shipping (the English / German communication was a slight hurdle but doable.) I am a reasonably competent parts changer, so I tackled removing the ABS unit. It is a pain. I also learned the BMW used 2 8mm Torx bolts, not Allen head type Torx fasteners, but Torx bolts. These two bolts are used to secure the ABS unit into it’s holder, and are difficult to access, and impossible to remove without the proper wrench. Not having Torx open end, or box wrenches, I found some on line and ordered a set of open end / box wrenches, and sockets. Add about $50 for tools that I may use this one time only, but you can never have too many tools, right?
So with only non-fatal bloodshed, an assortment of language that would make a sailor proud, and more than a beer or two, I was able to remove the ABS unit, and pack it up for shipping. RH warned to pack it securely as damage in shipping was not unknown. Took the unit down to my local UPS store, and with tariffs and everything it cost about $330 to ship to Germany. I was tracking the unit, and UPS Germany was having a hard time locating the shop, but a few email exchanges with RH, they were able to contact UPS and have the unit delivered, but instead of a week or so for shipping, it took close to three. AND THEN, RH sent photos of the box and the unit, and it looked like UPS backed a truck over it. I made a claim on UPS, they’ve not acted on it, so, being an attorney, I’ve sued - in small claims court. More fun.
In any event, RH said they could repair it for an extra $330 Euros. Instead of taking about 2 weeks to turn the unit around, it took about 2 months. In any event, the unit has been returned, with new parts, and looking shiny and usable - one hopes.
Next, the re-installation, filling the system with brake fluid, and bleeding.
Well, a few more curses, a few more bloody knuckles, and the unit has been installed. Next I bled the brake system, and much to my delight, the brake went through it’s self check, and now functions as if new.
Was it worth it, I like the bike, and it probably cost about $1,750 dollars to have the unit repaired. I dread to think what I would have had to pay a mechanic to do the work, even if I could find one that would be willing, with shop rates what they are these days. The choice was mine, not many of us hold onto a bike as long as I’ve had this one (but then I have a 1978 Ducati 900SS too). It certainly was cheaper than going out and buying a new bike, or a newer used bike. Would I do it again? Hopefully I won’t have to face that decision in the future, but I do recommend RH in Germany should you be considering it.
The first photo is the unit on the bench before shipping, the rest are the box as received in Germany, and the damage to the unit in the box.
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