Module Masters update for "Whizzy Brakes" - BMW iABS

Saw this posted on the BMWMOA site:
Happy New Year everyone and thank you for hanging in there while we developed a rebuild service for the iABS! In short we're done testing and we're waiting on parts to be finished and delivered. Here's the breakdown-

Q: What's been done?
A: Seals, fasteners and pump hardware have been produced. These parts as well as pressure sensors and motors have been tested and approved.

Q: What's left to do?
A: Get motors, pressure sensors and pressure sensor transducer IC's manufactured.

Q: How long will that take?
A: Each part has a different time frame. We're still trying to get more exact dates from the manufacturers. Here's where they were at as of the end of December.
Motors: Mid March
Pressure sensor transducer IC's: Potentially April. There weren't enough of these available in the USA, so they had to be ordered manufacturer direct with a 16 week lead time. These have been purchased and we're trying to see if the factory can get them produced sooner.
Pressure sensors: Originally told by the manufacturer they would arrive in December. Currently seeking a status update
Q: What's going to happen before the parts arrive?
A: We'll be finishing up our tooling for rebuilding the modules, writing up information for iABS instructions and will begin to pre-build the cores we've acquired. Also, we'll be producing a document of pre-ship information that will include what to remove, how to remove it and how to package the module. Info sheets will also be made detailing recommendations on re-installing, brake fluid type, batteries, bleed procedures, cleaning products (there will be messes) and what to do with problems on re-install. We will try to have these documents available to the waiting list folks before the rebuilds begin.

Q: How much will the rebuild cost when it's available?
A: $750 It will also include our 5-year warranty.

Q: What will the rebuild include when it's available?
A: New motors, new pumps, new pump seals (as well as other various seals), various new fasteners, new pressure sensors and a rebuilt electronic control unit. The unit will also be completely dismantled, cleaned, rebuilt and then tested (full hydraulic and electronic test).

Q: Will a core exchange be available?
A: Uncertain. We do have cores and intend to offer an exchange at some point but have not worked out any of the details yet. The non CAN-bus cores should be easy to exchange, but the CAN bus cores may require coding. We'll be doing more research to make the process as easy as possible.

A big thanks again to everyone who's been waiting. Updates will come every two weeks or so. We'll try and include some pictures of the process and things we encounter as we move forward.

Sincerely,

The ModuleMaster Team

Uncle Bob your at least as helpful as DRONE

I see a following already the making.

If I'm to live up to DB's image of me, I guess I have to post this list of bikes that use the iABS (or ABS III) brake system---->

• R1200GS (K25) – 2003, 2004, 2005, 2006 (part #: 34517698296)
• R1200GS Adventure (K25) – 2005, 2006 (part #: 34517698296)
• R1200RT (K26) – 2005, 2006 (part #: 34517698296)
• R1200RTP (K26) – 2005, 2006 (part #: 34517698296)
• R1200ST (K28) – 2005, 2006 (part #: 34517698296)
• K1200S (K40) – 2004, 2005, 2006 (part #: 34517698296)
• K1200R (K43) – 2005, 2006 (part #: 34517698296)
• K1200GT (K41) – 2003, 2004, 2005 (part #: 34517685801)
• K1200GT (K44) – 2006 (part #: 34517698296)
• R1150GS (R21) – 2003, 2004 (part #: 34517685790)
• R1150GS Adventure (R21) – 2003, 2004, 2005, 2006 (part #: 34517685790)
• R850R (R28) – 2003, 2004, 2005, 2006 (part #: 34517685790)
• R1150R (Rockster included) (R28) – 2001, 2002, 2003, 2004, 2005, 2006 (part #: 34517685790)
• R850RT (R22) – 2002, 2003, 2004, 2005 (part #'s: 34517685787, 34517685789)
• R1150RS (R22) – 2001, 2002, 2003, 2004, 2005 (part #: 34517685790)
• R1150RT (R22) – 2001, 2002, 2003, 2004, 2005 (part #'s: 34517685787, 34517685789)
• R1100S (R259C) – 2003, 2004, 2005 (part #: 34517685790)
• R1200C (259C) – 2004, 2005 (part #: 34517685799)
• R1200C Montauk – (259C) – 2004, 2005 (part #: 34517685799)
• R1200C Independent – (259C) 2004, 2005 (part #: 34517685799)
• R1200CL (and CLC) (K30) – 2002, 2003, 2004, 2005 (part #: 34517685800)
• K1200LT (K589) – 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 (part #'s: 34517685803, 34517685788)
• K1200RS (K41) – 2002, 2003, 2004, 2005 (part #: 34517685801)

You win DRONE, I just copied a post from the MOA.......
I really liked the whizzy brakes. This should help a lot of folks in the future.

you're

I feel like they have been saying for many years now that there were "on the verge" of being ready to rebuild these units... In fact, when the bmwrt.com/bmwst.com had their gathering in Moscow, the Module Masters folks invited everyone over for a BBQ - I didn't go to the BBQ (went for a ride instead - go figure!) but I did hear lots of talk at the bar that evening about how they were "almost" ready to go... that was...hmmm....2014? maybe earlier.

I hope they get it figured out, but I wonder how much of a market will be left by then.

I contacted ModuleMaster earlier this week. They are indicating they are on target to start rebuilding in April. They say one of the suppliers still has to provide them parts. I hope this is the case as I have a bike needing a ABS rebuild. There appears to be only three options 1) ModuleMaster around $750 2) RH Electronics $1600 or 3) BMW $3500.

Are these two the only source for rebuilding? I really don't like my fix of putting the black electrical tape over my idiot light.

I contacted Module Masters on July 12. They are still waiting for a parts manufacturer to ship motors for the ABS III module. Expectation is they will have them in 1 month.
Curious if anyone has experienced what I have with my '04 1150 GS? I have a seemingly random illumination of the brake warning light (lower triangle on steady) and 4Hz flashing of the upper Brake Failure light while riding. If I stop and restart the bike all is fine for anywhere from a few miles to >400 miles. The front brakes function normally, but the rear brake appears to have a servo malfunction.

Possible rear brake light switch issue it turns the servo on and the switch can be maladjusted and is in a vulnerable area.

davebid-interesting comment. I did a clutch job several years ago and raised the rear frame at a 45° angle. Sometime after that I began experiencing these episodic events with the brake warning lights. I won't review everything I did to identify/fix the issue, but it was a lot. One day I started tracing the wires at some distance to the ABS module and found the electrical connector on the right side of the passenger seat incompletely seated, ~1/8" out. This connects the rear brake pedal to the rear light and ABS module. I felt certain I had finally found the problem. It made perfect sense--I had partially dislodged the connection when raising the frame for the clutch job. Bike always started fine and I'd be able to go a few to a hundred miles before brake failure lights flashed. Stopping and restarting bike solved problem for a variable time period. I assumed that what was happening was the connection was good when riding and a hard bump likely transiently broke the electrical circuit through this point subsequently resulting in the brake failure warning. The immediate fix by stopping and starting bike was because circuit was again complete and it would take that random bump to transiently interrupt it again.

I had a good BMW dealer remove the absi at 82 k during a major service though the only trouble I had had was the rear brake light switch turning the pump on intermittently,I had an 04 K1200gt on a sidecar that when the brake lights failed it was in the logic board in the abs unit .

They're interested in showcasing their technological capabilities.

Their motorcycles will soon follow their automobiles: If you can't afford a new one you sure as hell won't be able to afford a used one.



.

While some of the ABS related failures are more complex, there were also indicator lights signalling failure when the bulbs were still activating. This was traced to the use of brass based after market bulbs in place of the OEM silver based bulbs.

Just got an 02 k1200lt and am really hoping they get their parts. They will be rebuilding 1000's of units.

I just watched the excellent video by Chrisnel on disassembling the ABS III (see link). When I removed the ABS module one of the 4 brake fluid lines attached to the top was dry, whereas the other 3 had brake fluid dripping from them. Based on Chrisnel's explanation the "dry" line was the line from the rear brake pedal (reservoir) to the module. The BMW tech when he was diagnosing problem with the ABS mentioned a pressure differential from ABS module to rear wheel circuit, but he also said he was measuring a really high temperature. He didn't offer an explanation for the temperature reading. I'm guessing the only thing in the module capable of producing heat is one of the 2 motors. If true, 4 possible causes seem likely-a stuck pressure release valve, a plugged filter on output connector, a defective pump or a stuck piston connecting input and outflow chambers. I don't know if a failing motor would cause heat buildup. (Rear brake reservoir is full, metal brake line to module is not kinked and switched OEM rubber brake lines for SS many years ago). Too bad BMW won't sell parts for the module as it is far easier to disassemble/reassemble than doing a clutch job.

https://advrider.com/index.php?thre...s-3-integral-abs-dismantling-rebuild.1329521/

This was just posted to the IBMWR mail list:

Just a quick update- the motor armatures are finished in manufacturing and
we're working on getting them through customs. Once the motor parts
arrive, there will be a bit of a wait while we turn them into fully
function motors and pump assemblies. Once the assemblies are complete
we'll begin on the waiting list. If all goes well, we should be able to
get a sizeable chunk of the waiting list served in October. If you haven't
submitted your part number yet, please do so! It'll will help speed up the
turn around time.

If you have any questions on the process, feel free to ask! Thanks again
for waiting along with us.

Sincerely,

The ModuleMaster Team
abs3waitlist@modulemaster.com
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Sent the ABS module from my '04 1150 GS via UPS Ground to ModuleMaster on 9/26 and it was returned 10/12, also via UPS Ground. Subtracting the shipping time it took about a week for the rebuild. Tyler at ModuleMaster emailed me pictures of the broken pump to rear wheel circuit. On 10/15 I reinstalled the ABS module and bled the control and wheel circuits, using the servo pumps to bleed the latter. Everything worked fine during bleed. Unfortunately I have contracted a wicked cold and have yet to road test the bike, but based on the results of the break bleed have every confidence it is repaired. The rebuild was $750 and the 5 year warranty from ModuleMaster is conditioned on annual brake fluid flushes.