Will anyone in the USA rebuild the ABS control module?

[Jdandy]

Found it

 

[Jdandy]

Really appreciate the help. Cleared codes per shop manual and afterwards I got 6 quick blinks and two longer spaced blinks "62". Looks like it is undoubtedly a bad ABS pump.

 

[Mark Gonzo]

My abs light came on getting out of mud.
Turned off traction control and gave it the beans. ABS light came on and didn’t reset.
Got lucky - have a parts bike and my shop swapped it out.
Still was an expensive repair but didn’t have to buy a new pump.
Have heard of bypassing the pump.
Good luck.

 

[Jdandy]

My abs light came on getting out of mud.
Turned off traction control and gave it the beans. ABS light came on and didn’t reset.
Got lucky - have a parts bike and my shop swapped it out.
Still was an expensive repair but didn’t have to buy a new pump.
Have heard of bypassing the pump.
Good luck.

That is good. Looks like I am going to need a module. Is your bike a GEN1 ? That ABS has saved me on more than one occasion. Will get fixed and move on.

 

[audiowize]

I believe if you check the parts diagrams that the Gen 1 and Gen 2 ABS blocks are the same.

 

[Jdandy]

I believe if you check the parts diagrams that the Gen 1 and Gen 2 ABS blocks are the same.

My concern would be any upgraded programming that would not be supported by the ECM...thoughts?

 

[Jdandy]

Yamaha corporate response to inquiry:

After explaining the deficiency in the subject item I was advised the bike "was out of warranty"...NO JOKE!! After explaining that this was a known problem
with GEN1 bikes and that Yamaha had "actual and constructive notiice" of this deficiency and made changes accordingly to the GEN2 bikes the "Boiler Plate" response was:
"You can take it to a dealer and let them evaluate and submit an OUT OF WARRANTY claim and the maximum we can compensate is $250.00.

Option 1 DEALER REPAIR
$ 2400.00 +
250.00 -
$ 2150.00 Out of pocket.

Option 2 ORDER PART AND COMPLETE REPLACEMENT
$1640.00

This could be fertile ground for class action.....could warrant further investigation.


///////////////////////////////////////END OFMISSION////////////////////////////////////
-

 

[audiowize]

You want to sue Yamaha because something broke on your 10-year-old bike and needs to be fixed? If you own the bike another 10 years and wear out the engine, are you going to call and complain and ask them to pay for that too?

The generic corporate response would be to ask you to submit your maintenance records to show that the brake fluid has been changed at least every two years before offering any kind of assistance to you.

 

[audiowize]

My concern would be any upgraded programming that would not be supported by the ECM...thoughts?

They are off by a digit, so one could imagine a scenario where the design was tweaked slightly but is otherwise compatible. Depending on where you live, there may be someone close by who would let you try plugging one in to see. The lack of supersession on the original part number could mean that they aren't compatible or that the original ABS blocks are still sitting on shelves and need to be sold.

 

[WJBertrand]

Has anyone reported these ABS issues to the NHTSA? If there are enough complaints they might open an investigation. I don't think it would matter how old the bike is or its warranty status.

 

[RCinNC]

If the ABS pump fails on my bike I'm absolutely going to be pissed, but it's too easy to fall into the confirmation bias trap when you read about equipment failures on a motorcycle forum. There's no way to determine an actual failure rate of this part based simply on the self reported occurrences on a motorcycle forum. It may very well be flawed, and it may very well not be flawed and the number of failures of this particular pump is well within the life expectancy of the unit that the engineers came up with when they designed it. If this is a Bosch part, I have no idea how many of them that Bosch has sold and installed in other applications besides the Super Tenere. If they sold 50,000 of them and 10 guys have had failures, is that an acceptable rate? Beats me. But I think you're worlds away from class action status for this. Superseding a part with a new one isn't evidence of in and of itself a design failure; it could simply mean that the design was changed in order to meet some new parameter (like manufacturing the part in a new way to make it cheaper). Or they changed subcontractors to make the part. Or the part was crap and prone to failure. It could be any of those reasons.

It seems like every bike has a "thing" like this, that forums help perpetuate. With V-Stroms it's the stator, with KLR-650's it's the doohickey, with FJRs it's the rear subframe, and even the Gen 1 Super Teneres have the cam chain tensioner issue. We end up reinforcing the idea that the part is flawed because all we read about are the failures. Ten guys reporting failures on a forum can make it seem like a problem is endemic, but it's impossible to draw an accurate conclusion from that sort of data.

This part may well be prone to failure, but it's too easy to draw erroneous conclusions from the anecdotal evidence on a motorcycle forum.

 

[Jdandy]

You want to sue Yamaha because something broke on your 10-year-old bike and needs to be fixed? If you own the bike another 10 years and wear out the engine, are you going to call and complain and ask them to pay for that too?
66u5h4

You want to sue Yamaha because something broke on your 10-year-old bike and needs to be fixed? If you own the bike another 10 years and wear out the engine, are you going to call and complain and ask them to pay for that too?

The generic corporate response would be to ask you to submit your maintenance records to show that the brake fluid has been changed at least every two years before offering any kind of assistance to you.

The generic corporate response would be to ask you to submit your maintenance records to show that the brake fluid has been changed at least every two years before offering any kind of assistance

[audiowize, post: 499836, member: 29255"]
You want to sue Yamaha because something broke on your 10-year-old bike and needs to be fixed? If you own the bike another 10 years and wear out the engine, are you going to call and complain and ask them to pay for that too?

The generic corporate response would be to ask you to submit your maintenance records to show that the brake fluid has been changed at least every two years before offering any kind of assistance to you.

Look.....when it becomes known that a certain critical safety item on anything has a high failure rate or high chance of failure and the manufacturer has "actual or constructive" notice of the deficiency it should be incumbent on that manufacturer to remedy the issue. There are bikes with inherent known issues that do not directly impact safety....doohickey on KLR to mention one. This is not a critical safety item.. There are safety recalls on automobiles that sometimes do not materialize for years after a manufacture date. Had a safety item problem with a 2011 Sonata and the recall was not published for 6 years. They did not ask to review my maintenance history on the subject vehicle, it was repaired no questions asked. After Hyundai had their keister handed to them on a death claim for a related issue they suddenly had an epiphany.....whodathunkit.

I am not a litigious individual however, I have sat in on meetings over the years where value of human life was weighed against the cost of the remedy. Sometimes it takes a long arm reaching into coffers to get deserved attention. As much as I detest being bombarded with commercials from trial later after trial lawyer they are sometimes a necessary evil.

 

[Jdandy]

Under what fault code does the light come on?…..it could be a momentary power failure, a momentary loss of signal, the pressure sensors are no longer there, because you said that the light came on without applying the brakes….if you don't delete the fault codes, the light will remain on, just to remind you that you have a fault detected and stored in memory
If you put a new module, and the fault is elsewhere, but related to the module... you won't solve the problem...

Checked for momentary power failure....13.6 -14.4 v @ coupler with bike running. 12.8 V without running.

 

[Jdandy]

If the ABS pump fails on my bike I'm absolutely going to be pissed, but it's too easy to fall into the confirmation bias trap when you read about equipment failures on a motorcycle forum. There's no way to determine an actual failure rate of this part based simply on the self reported occurrences on a motorcycle forum. It may very well be flawed, and it may very well not be flawed and the number of failures of this particular pump is well within the life expectancy of the unit that the engineers came up with when they designed it. If this is a Bosch part, I have no idea how many of them that Bosch has sold and installed in other applications besides the Super Tenere. If they sold 50,000 of them and 10 guys have had failures, is that an acceptable rate? Beats me. But I think you're worlds away from class action status for this. Superseding a part with a new one isn't evidence of in and of itself a design failure; it could simply mean that the design was changed in order to meet some new parameter (like manufacturing the part in a new way to make it cheaper). Or they changed subcontractors to make the part. Or the part was crap and prone to failure. It could be any of those reasons.

It seems like every bike has a "thing" like this, that forums help perpetuate. With V-Stroms it's the stator, with KLR-650's it's the doohickey, with FJRs it's the rear subframe, and even the Gen 1 Super Teneres have the cam chain tensioner issue. We end up reinforcing the idea that the part is flawed because all we read about are the failures. Ten guys reporting failures on a forum can make it seem like a problem is endemic, but it's impossible to draw an accurate conclusion from that sort of data.

This part may well be prone to failure, but it's too easy to draw erroneous conclusions from the anecdotal evidence on a motorcycle forum.

You are correct. However, auto manufacturers seem to be much more responsive to items directly regarding safety. It costs a small fortune to perform the necessary research to initiate a class action so there are probably not enough GEN1 S10's out there to concern Yamaha. Apparently their remedy was to address this issue and correct on GEN2 and let the legal department make an actuarial decision on their liability exposure on this issue. "Foller the doller"

 

[Jlq1969]

Checked for momentary power failure....13.6 -14.4 v @ coupler with bike running. 12.8 V without running.

You are only measuring the voltage on the abs on the hot wire…..if for a fraction of a second, the module loses ground….it would be the same as losing voltage on the hot wire……
The problem is that you are thinking that the module is faulty…..and I am thinking that the problem is an electrical connection…..I don't remember having read a fault like the one you have…..and if there is any abs fault in the forum, I think that in the vast majority of cases there was an erroneous manipulation of the rear pads and outside of what is recommended in the service manual
You say that the module fails "when it gets hot"......fill the receptacle with ice...and go out and test it

 

[Jdandy]

You are only measuring the voltage on the abs on the hot wire…..if for a fraction of a second, the module loses ground….it would be the same as losing voltage on the hot wire……
The problem is that you are thinking that the module is faulty…..and I am thinking that the problem is an electrical connection…..I don't remember having read a fault like the one you have…..and if there is any abs fault in the forum, I think that in the vast majority of cases there was an erroneous manipulation of the rear pads and outside of what is recommended in the service manual
You say that the module fails "when it gets hot"......fill the receptacle with ice...and go out and test it

Now that's an idea. I havre it torn down at a friend's shop and it will fail when it runs a out 5 minutes other centerstand.

 

[audiowize]

Have you double checked that there are no shorted mosfets in the module? You can do this easily with a $25 multimeter from Harbor Freight and there are ample YouTube videos that show how to do this (it's a common process in repairing car audio amplifiers).

 

[Checkswrecks]

Has anyone reported these ABS issues to the NHTSA? If there are enough complaints they might open an investigation. I don't think it would matter how old the bike is or its warranty status.

NHTSA has a single investigator in the Office of Defect Compliance (iirc that is the name - ODC).
I wouldn't even consider logging your complaint about a low production 10 year old bike having something not work.

 

[Jdandy]

Have you double checked that there are no shorted mosfets in the module? You can do this easily with a $25 multimeter from Harbor Freight and there are ample YouTube videos that show how to do this (it's a common process in repairing car audio amplifiers).

I have a good multimeter......just not sure what a mosfet is. This is a sealed unit and there is no access to the integrated circuit board that I can find. I am going ahead and purchasing o e of the used ABS pumps and I will send the original pump to central America with a friend to a shop that can repair it if it is repairable.

 

[audiowize]

The mosfets are the three legged devices mounted to the heatsink. They are the heavy lifters that do the work of actuating the solenoids. Your meter should not show a low resistance between any pair of pins in both directions.