2008 G650X-Challenge ABS valve relay fault

[GT]

This fault started when the battery was allowed to run low through lack of use.
Originally wanted to purchase non-ABS model due to knowing that there would be issues down the track, but they only had the ABS ones left during a run out special a number of years ago.
So the ABS failure has been convenient for me so I didn't have to remember to turn the ABS off all the time, but am now looking at moving the bike on, so getting the ABS functioning for resale purposes.

Had bought a second hand X-Country ABS unit that was stated as working when bike was dismantled, but GS911 indicates it has exactly the same error.

Just trying to work out whether I need to find yet another ABS unit or whether this "valve relay" can be repaired?

Per the attachments, the ABS Status shows that the valve relay is under half the battery voltage. Wondering whether this could be a fault in wiring?
Opened the original ABS unit to check whether there was a replaceable valve relay, but it seems on the left hand side, there is a diode and a pair of FETs, so guessing the valve relay is part of the circuit on the right hand side of the picture? which is encapsulated.

Searched internet for this type of fault but had absolutely no luck.

Copy below of Autoscans for both ABS units

Thanks for any help,
Greg

AutoScan Report
GS-911 version: 1612.7 Datapack version: 7.1
Serial Number: GS40006201
Firmware version: 0.21.A
Date: 1/01/2017 Time: 11:34:44 AM

Motorcycle Information
VIN: WB10165048XA82987
Mileage: Not available

BMS-C II
Part No.:    0007706346
HW Version:    A
Diagnosis Index:    5
Manufacturing Date:    2007-06-21
HWOE No.:    27920974
Program release:    200E
Manufacturer:    Hella
Data release:    200EN61B
Operating time:    599h 31m 20s
VIN:    WB10165048XA82987
VIN model year:    2008


No fault codes found

ABS8M
Part No.:    7704843
HW Version No.:    C1
Coding Index:    0
Manufacturing Date:    2006-09-26
HWOE No.:    27941702
Manufacturer:    Bosch
MCV:    0.0.0
FSV:    0.0.0
OSV:    0.0.0
VIN:    XA82987
Variant:    K15 HE Hardenduro (Xchallenge)


1 fault codes found:
25488    Pressure modulator: Valve relay
The fault is currently present.




AutoScan Report
GS-911 version: 1612.7 Datapack version: 7.1
Serial Number: GS40006201
Firmware version: 0.21.A
Date: 31/12/2016 Time: 5:13:00 AM

Motorcycle Information
VIN: WB10165048XA82987
Mileage: Not available

BMS-C II
Part No.:    0007706346
HW Version:    A
Diagnosis Index:    5
Manufacturing Date:    2007-06-21
HWOE No.:    27920974
Program release:    200E
Manufacturer:    Hella
Data release:    200EN61B
Operating time:    599h 16m 29s
VIN:    WB10165048XA82987
VIN model year:    2008


No fault codes found

ABS8M
Part No.:    7704843
HW Version No.:    C1
Coding Index:    0
Manufacturing Date:    2006-09-26
HWOE No.:    27941702
Manufacturer:    Bosch
MCV:    0.0.0
FSV:    0.0.0
OSV:    0.0.0
VIN:    XB20032
Variant:    K15 SC Scrambler (Xcountry)


1 fault codes found:
25488    Pressure modulator: Valve relay
The fault is currently present.

[Caspar Berends]

Hi,

Have you replaced battery with fully charged one? Often that solves issues.

Sendt fra iPhone min

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<g650xchallenge_abs_fault1.jpg>

<Dsc_0233.jpg>

[GT]

Brand new BMW battery fully charged.
When the battery is first connected, speedo display shows diagnostics and abs light comes on. When ignition on, abs light stays on (normally blinks).
Cleared fault code, disconnected battery for 5 minutes then reconnect. Abs fault back.

[GT]

BTW. Happy New Year to everyone.

[Ducdude]

Yes the very happiest of new years to all..

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[Gavin Powell]

Hi Greg

 

I only got my GS911 at Christmas so am very new to the technology. That said I have already cleared a faulty exhaust flap in my R1200GS with the aid of the GS911 so really please with it.

 

I have read through my Haynes manual on the subject of ABS and it was not far short of useless to your issue. The only logical thing I can think that may help is that:- If the exact same fault code appears with both ABS units then it is likely, to me, that the ABS unit is not the cause fault code. Unless they both have exactly the same issue which is not that likely but not impossible I agree.

 

The only practical information I found online was an YouTube video about an issue with the brushes on the ABS pump motor.

https://www.youtube.com/watch?v=6m2H-nC0CqE

 

All the best with this issue

Gavin

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[Phil]

Hi

Due to the nature of the bike, and to the events immediately preceding the error i would suggest you check all connections and voltages in the loom before you do anything else.

If it stood long enough to wreck the battery, its long enough for black lead corrosion, or indeed any corrosion of wires.

Most likely are earth errors, but check all plugs for any sign of corrosion or loose contacts. Not a bad time to use dielectric grease as well.

Phil

[GT]

Hi Gavin,
Thanks for your post. Agree that it is strange that both ABS units have exactly the same error. Suspect something else as well.

Hi Phil,
Thanks for your analysis. Agree that it might be a connector terminal somewhere. Have checked the ABS and computer (large connectors) pins and they appear clean with no corrosion. Used contact cleaner on them as well.
Will try other connectors but difficult to determine what is what without a circuit diagram. Unfortunately, the G650X RepROM doesn't have anything.
Had an issue with the ignition switch when it was about a year old where it was intermittent to switch on. Pulled it apart and found bad solder joint from one wire to switch terminal. Amazed that it even made any contact over that first year. Re-soldered and all was good.
Could be an indication of the quality of work with these models though. A lot a Aprilia components.....

When checking the ABS Status on the GS911, the valve relay voltage is always about 1 volt lower than half the battery voltage. When running the engine while monitoring, it will fluctuate up and down accordingly. Almost like there is a resister in the circuit to the valve relay.
So Phil, I think you might be on the money regarding corrosion of contacts. Will investigate further this coming weekend.
Cheers
Greg

[GT]

Just found a link to G650X circuit diagrams.
http://www.ukgser.com/forums/showthread.php/213635-XChallenge-Wiring-Diagram/page2

[Phil]

Hi

I dont have a schematic but be aware that a lot of modern, post 60`s designs dont have an earth return in the loom. They rely on that dirty big lump of metal in the centre.

As such you have to check the earth straps to that lump, be it frame or engine. And the bolts that hold bits on.

Dont rely too much of voltages reported by diagnostics etc as they are not designed to be accurate, just as a ballpark figure. A dvm or avo is a better bet, and the same one for all measurements at that. Using the main battery terminal as the earth. Oh and check the voltage of all metal components against this. If you are lucky you will find a voltage difference to show you a bad earth. Has to be under load though, ohms law.....

I will say that a bad earth does usually represent as a resistance, dim lights etc, long before full failure of connection.

Phil

[GT]

Hi All,

Well, it's fixed.
The schematic was a great help.
ABS ground is a direct link back to the battery -ve terminal and all was good there.

Pulled the rear end off yet again to access the ABS connector. Pins 1 & 4 were ground and 2 was main +ve and pin 3 was secondary +ve. Checked continuity to 1,4 & 2. All good. Thinking hit another brick wall, checked continuity to Pin 3 (red/black wire). Zip. Doh! Checked from battery terminal to fuse. OK. Fuse to ABS was zip. So started unwrapping harness tape to probe further. Pulled red/black wire from fuse box and voila! Looks like the wire was sliced at some stage in the factory and finally let go. The green corrosion indicates that the slice may have been there for quite a while. Apart from a one time Captain Nemo episode, any further moisture would have been from rain which would not have been able to access that region.

Anyway, all good now and the original ABS unit is still good (tested). Cleared fault code and ABS status indicates valve relay voltage higher than battery.
Easy to replicate this fault by removing the 20amp ABS fuse given what I know now.......

Thanks to all for your input and help.
Cheers,
Greg

[GT]

ABS Status snapshot after fix.

[Eddie Whitehead]

Well done. Thanks for all comments, suggestions and feedback. I think this forum is great stuff and extremely helpful to us all.

Nice work and congratulations on solving the problem.

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[GT]

GS911 tool is fantastic.
Would be dead in the water without it.
Had an R1150GSA and loved it. When the R1200GS came out, didn't want to upgrade due to the new CANBUS system. When GS911 announced, upgraded to R1200GSA and never looked back. The 1200 was doughy compared to the 1150GSA until fitted full staintune exhaust and lenny sprockets. A non-ABS R1200GSA with computer option, and now with E07 Mitas tyres. Fantastic for commuting and adventure travels.

Thanks to Stephen and crew at Hex for such a great tool. Would be lost without.
Cheers,
Greg

[Mole C]

good trouble shoot

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Maurice

[Trevor Williams]

Well done for finding this tricky fault. Go ride now on some dirt.