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Discussion Starter · #1 ·
My 2008 K1200GT turned on the Brake Failure light, constant on during my first ride of the season. I have seen lots of posts with the codes from a GS911, that confirm this is the pump motor brushes.

I am using an OBDLink MX with Motoscan and get codes 5DF0 and 5DF1, both say "Pump motor: Voltage Supply". I have been able to actuate the pump motor a few times, but it is very intermittent.

Can anybody confirm if the 5DF0 and 5DF1 codes are also brush failure?
Module Master lists the codes like this>
Code 24048 (5DF0)
Code 24049 (5DF1)
 

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My 2008 K1200GT turned on the Brake Failure light, constant on during my first ride of the season. I have seen lots of posts with the codes from a GS911, that confirm this is the pump motor brushes.

I am using an OBDLink MX with Motoscan and get codes 5DF0 and 5DF1, both say "Pump motor: Voltage Supply". I have been able to actuate the pump motor a few times, but it is very intermittent.

Can anybody confirm if the 5DF0 and 5DF1 codes are also brush failure?
Module Master lists the codes like this>
Code 24048 (5DF0)
Code 24049 (5DF1)
100% standard designed in failure for this module....

the great bit about the K1300GT is the module is to the left of the petrol tank and should take you around 30 mins to get it off the bike vs the 5 hours first time I did it on the GS. Left faring panel off and its just sitting there.... brake fluid will go every where.... I'd probably put it in a plastic back as you remove to collect it all... and make sure a new one is there to collect the drips.

the pump motor needs to come off or if your lazy a small hole and lots of contact cleaner in situ will probably fix it for another 2 years - not sure about USA but you can post to these guys for UK riders - you must enclose the info on the two faults.... those two are generic across BM cars and bikes

https://www.ecutesting.com/product-catalogue/bmw/k1200/abs-pump-ecumodule-combined/ ABS11 bikes on GS and K series use the same module...

youtube videos if you want to tackle yourself but at 1200 for a new one and 250 for guaranteed repair why bother.... the other point about DIY is how do you re-crimp the motor correctly, not something you want to fall off
 

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Discussion Starter · #3 ·
Thanks for the reply botus, yes I've got the fairing off already. I'm surprised at how bulky the unit is for a motorcycle, almost identical unit as many cars including BMW.

Ive watched all the videos on self repair, which I plan to do as well. Will report back how it goes.
 

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Discussion Starter · #5 · (Edited)
I completed the repair on this a few days ago, had to wait 5 days for a new SKF bearing to show up :)
All that was needed was to scrape down the brushes a little bit, it was obvious that the brush housing was squeezed just a few mils to tight. A little scraping with pocket knife and they slide in and out perfectly.

https://www.k-bikes.com/forums/attachment.php?attachmentid=24543&thumb=1
Cleared the 5DF0 and 5DF1 codes with Motoscan, and tested motor actuation. Working perfectly. Bled the brakes, and road tested, ABS is working great again!

One thing that is strange though, is every time I turn the bike on, the panel shows "Brake Failure" until I drive off. Then warning goes out. I have read codes and none are stored. What does this mean? is there something else that needs to be reset?
 

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Anyone have a link to those videos? My "Brake Failure" light just started flashing. The brakes work, but man I gotta pull that lever hard now.
 

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Discussion Starter · #10 ·
2 years later, an update: got the same ABS failure and 5DF0 and 5DF1, "Pump motor: Voltage Supply” codes. Pulled the pump motor (easy now because it is just screwed on) and found brushes stuck again. Turns out shaving wasn’t quite the right fix. It seems the rear of the brush is what is sticking. I was able to stick a screwdriver in the braid slot and pry the housing open slightly. Moving good again, installed and pump runs great. Hopefully get more than 2 years this time!
 

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Discussion Starter · #11 · (Edited)
Another year and problem came back. This time i found a replacement! A 2014 Ford Focus uses an identical looking ABS module, I bought used one on eBay for $45. On comparing them, the motors are identical EXCEPT the armature with the eccentric has MORE deflection on the eccentric shaft that sticks out. So, I used my original motor armature and put it in the Ford Focus motor housing, and it is working great! Permanent fix this time i hope.
Product Font Wood Auto part Machine


This photo is just to show how the corners of the motor are clamped with screws into the ABS housing, this is the original BMW motor:
Computer hardware Electronic device Electric blue Font Cable
 

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who pulled my post ? as I had said ABS module on later bikes..

read and weep

SIB 34 03 20
SERVICE ACTION: ABS Modulator Mounting Bolt
2021-06-14
This Service Information Bulletin replaces SI 34 03 20 dated October 2020.

During assembly, an additional mounting bolt was installed on the ABS pressure modulator instead of a plastic rivet. This changes the vibration behavior of the ABS modulator. When the motorcycle is frequently used at very high engine speeds, vibration damage to the components could occur.

CORRECTION
The additional bolt must be removed and a plastic fastener (rivet) must be installed in its place.

PROCEDURE
For vehicles that are affected, please replace the bolt by following repair instruction “00 60 369 – Screw connection ABS pressure modulator”, attached.

PARTS INFORMATION
Part Number Description Quantity
61 21 7 659 147 Plastic Rivet 1
 

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So BMW mistakenly replaced a plastic rivet with a steel bolt during assembly, confirmed that it could cause excessive ABS module vibration at higher engine speeds, then created a Service Bulletin to remove the steel bolt and replace the plastic rivet.

Where in that does it specifically say anything about planned obsolescence?

These sorts of Service Bulletins happen all the time, to pretty much all vehicle manufacturers. In fact, an SB is the official BMW mechanism for solving these types of issues at their own cost once they're noted and confirmed.

BMW is far from perfect, to be sure (just check out my avatar). But this is really much simpler than you think it is.
 

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So BMW mistakenly replaced a plastic rivet with a steel bolt during assembly, confirmed that it could cause excessive ABS module vibration at higher engine speeds, then created a Service Bulletin to remove the steel bolt and replace the plastic rivet.

BMW is far from perfect, to be sure (just check out my avatar). But this is really much simpler than you think it is.

don't jump to conclusions - read that document and you'll see it replaces an earlier document - the earlier one explains to model year xxx they ONLY ever used the plastic rivet on the bikes - then upgraded all later model year bikes worldwide with the metal bolt (thus introducing the fault) - but they have for the US market had to reverse out of the situation they introduced and are repairing the issue BUT have NOT done the same in other markets, nor made any other markets aware of the enhancement


AKA a class action law suite caught them by the short and curly's for one market and they are making money elsewhere
 
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