GS-911 User Forum

General Category => Technical => Common trouble codes or bike issues with known solutions => Topic started by: kobus on April 18, 2013, 05:40:55 PM

Title: Integral ABS 2 - CAN "Power Supply to Pump motor faulty" 24048(0x5DF0)
Post by: kobus on April 18, 2013, 05:40:55 PM
Symptom:
On the "Integral ABS 2 - CAN" control units a common error is the following:

24048 Power Supply to Pump motor faulty.
24049 Power Supply to Pump motor faulty.

Solution:
Usually the cause is that the brushes of the ABS pump motor are shorted or stuck to the motor housing.
Some brave people have opened the ABS module and fixed the pump motor.
Knocking the unit with a rubber hammer might temporarily fix the issue.

Prevention:
Keep the battery properly charged.
We suspect that a battery that is not properly charged increases the motor current and shortens the life of the ABS pump motor.
Be careful with the high pressure hose.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: StephanT on April 18, 2013, 11:24:37 PM
Just for clarity, the "Integral ABS 2 CAN" control unit is the second generation (non-Servo) ABS used on the K24 models (i.e. CAN-bus models  as of late 2007)

best,
Stephan
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jos on April 22, 2013, 09:18:38 PM
Hi all,

Attached some pictures from the Google group (posted by jebo) that explain what to do.

Best,

Jos
 
 
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: kobus on April 23, 2013, 09:46:44 AM
Thanks Jos!
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Greenvetter on April 27, 2013, 05:20:02 PM
Hi,
I did this repair last weekend. I pulled the pump rather than attempt it in the bike as other forums have suggested. Other than drilling the holes in the motor to get at the release tabs it's not too difficult. I-BWM great write up with links to a youtube video. A GS911 is mandatory for error verification and bleeding. My bike is a K41 07 1200GT.

Great product and software!

Thanks.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jos on April 28, 2013, 04:15:29 PM
Hi,

Thanks for your input.
Could you please post the link to the I-BMW write up and the video?
Would be very helpfull for other users.

Best,

Jos
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jvosum on July 17, 2013, 10:21:24 PM
Hi,
for those, who are not so skilled in searching on Youtube, this is probably the video: http://www.youtube.com/watch?v=oyUvwwBQg0A (http://www.youtube.com/watch?v=oyUvwwBQg0A)

Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on August 16, 2013, 10:24:26 PM
Hi,
for those, who are not so skilled in searching on Youtube, this is probably the video: http://www.youtube.com/watch?v=oyUvwwBQg0A (http://www.youtube.com/watch?v=oyUvwwBQg0A)



For those interested, I have all the tooling to split, refurbish and re-assemble these pumps WITHOUT drilling huge holes in the motor casing.

I provide an 8hr turnaround time on the repair.  In fact, if I receive it early enough in the day, it can be returned via courier the same day.

Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Haakon on August 18, 2013, 01:00:39 AM
Just a comment to "Kobus"`s first post:
A low voltage WILL fry the brushes and motor commutator.
Or make the brushes "weld" to the brush housing.
 
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Beamietoo on August 18, 2013, 05:36:36 PM
Anybody know where to get replacement brushes if the are fryed ?
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on August 18, 2013, 05:46:58 PM
Your local Bosch Autoelectrical outlet.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Beamietoo on August 18, 2013, 06:00:11 PM
Thanks Jughead !!
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Bikecare on November 14, 2013, 09:15:45 AM
Hi all,

I had the same problem and I did repair myself last Sunday.

Here the video:
feature=c4-overview&list=UU2KJA52RymcDoE50E2hOgxA

Hope it helps!
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Paul90 on November 15, 2013, 04:45:11 PM
+1

Had the same problem, same GS911 codes.

I dismantled the pump based on info from here cleaned / freed off the bushes and it's all fixed  :)

+500 trouble free miles now.

Paul
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Bernard on November 18, 2013, 03:22:07 PM
Hi guys!

Got the same fault codes on a GS Adventure I'm working on. Followed the procedure in this post. Reassembled, reinstalled & bled. Initialization went well & warning lamp turned off as it rolled off. Thought I had it in the bag, til I hit the brakes. ABS warning lit & went steady. Plugged in GS-911 & found the same fault codes present & wont be cleared. Carbon brushes are still very long, tension on the springs are pretty good, when I dismantled the motor. Commutator & other contacts cleaned & checked but still went back to square 1, after a short road test. Any recommendations or suggestions, on what might went wrong?

Thanks in advance!

Bernard R. 
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Bikecare on November 18, 2013, 04:16:10 PM
After reassembling motor itself (before fitting to aluminum pump), did you measure the motor coins and test run by applying 12VDC to the motor connector? You also should rotate by hand the axle of motor to be sure it's running lightly and no any hitting, knocking inside the motor otherwise the motor can be damaged after short ruuning.

The brushes are may be long, springs are maybe good, but the moving of brushes inside square metal pipe must be very smoothly and lightly.

Do not apply any oil or grease on the brushes.

Open again and re-check...
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on November 18, 2013, 04:38:59 PM
Hi guys!

Got the same fault codes on a GS Adventure I'm working on. Followed the procedure in this post. Reassembled, reinstalled & bled. Initialization went well & warning lamp turned off as it rolled off. Thought I had it in the bag, til I hit the brakes. ABS warning lit & went steady. Plugged in GS-911 & found the same fault codes present & wont be cleared. Carbon brushes are still very long, tension on the springs are pretty good, when I dismantled the motor. Commutator & other contacts cleaned & checked but still went back to square 1, after a short road test. Any recommendations or suggestions, on what might went wrong?

Thanks in advance!

Bernard R.

I rebuild possibly 2 of these pumps a week and have had a 100% success rate, thus the reason for being able to provide a 5 year warranty on the job.  There is only one way to do this correctly.  Remember that it is an integral part of the brakes, which, on a bike, are one of the life and death components.

I replace the bearings and brushes.

I have all the tooling to dismantle the pumps without drilling huge holes in them, as well as the tooling to reassemble them as they were in the factory, ensuring that they don't fall apart again.

I normally charge a flat rate for the complete rebuild.  However, since yours has now already been dismantled and reassembled once, that flat rate would no longer apply.

As to what can be wrong, it is very difficult to say.  It would have to be stripped again to see.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Bernard on November 18, 2013, 04:55:56 PM
Thank you for your reply Jughead. I believe it would be best for me to open it up again tomorrow & try replacing the brushes & bearing, as you suggested. It's good to know that you do this on a regular basis, hence I'll keep you posted on my progress & shoot any questions, should I have anymore, after tomorrow's 2nd attempt.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Bernard on November 18, 2013, 05:00:25 PM
@ Bike Care: Yup! Exactly what I did before reassembling the motor back to the pump, just to be sure, that it would run flawlessly. Honestly, been doing a lot of repairs on my end but this is my 1st ever ABS Gen-2 repair. I'm quite familiar with the structure of the motor itself, since the principle applies to most common motors. I'm pretty sure I did what I'm suppose to; would there be any other cause for these fault codes to show up, other than the motor? ie: The control unit, not giving the required signal or voltage?

Appreciate your immediate reply.

Bernard R. 

(thought this message went through)
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Paul90 on November 18, 2013, 06:08:31 PM
Obvious things to check would be battery, wiring, connectors, etc but I expect you have already done that.

I think it's most likely something in the motor.
Did you clean out all the carbon bits from where the bushes had worn ?
They were liberally sprayed about inside mine (@ 50k miles) and I cleaned it all up.

And also try running the motor from a 12V source before reassembly.
Oh, and give it solid "tap" with a rubber mallet before you take it all apart again just to see if it clears.

Paul
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Bikecare on November 18, 2013, 06:22:34 PM
Bernard,

If you are sure the motor has been repaired correctly, and you are sure the faulty code also the same (power suuply to pump motor faulty), then I would check the two connectors of power supply by removing control unit oposite side of motor (now it's more easy than to remove again motor). Only be very carefull with some very small springs as connector inside.

Check the male and female connectors, clean all of them. If the female connectors on the motor side to open, you can twist lightly male connectors or use thin copper sheet to increase thickness of male ones.

The faulty code: power suuply to pump motor faulty shows the problem must be only either inside motor or some where closed to the motor, no where else.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Bernard on November 20, 2013, 04:20:04 PM
Hi all!

Thanks very much for all your suggestions, truly appreciate each & everyone's advise! Before discussing my on going repair with the GSA; I just want to let you guys know that I just finished an R1200GS Standard today(also with Gen 2 ABS Mod), with the same fault codes as the GSA.

This time, when I got the motor off the mod, I checked if it would run through an external power source & found the same to be stuck. I decided to set it aside for the time being, as clearly this was the cause of the problem & used the motor from the GSA as a test part. (I wanted to know if  the motor of the GSA will work on the 12GS' mod, since I know that it was reassembled right.)

After installation, the 12GS' ABS worked flawlessly. Took it out for a few kms & did several stops, just to check, if it would initialize on start up & activate on roll off. I can't be happier with the results, as it worked perfectly, each & every time. At this point, I'm pretty sure that the cause of the problem on the 12GS' ABS, was really the motor.

Being the case, it did not just prove, that the motor of the GSA was done right but also proved, that it wasn't the source of the problem, under the same fault codes. Most of the suggested recommendations stated, I've already tried & checked & none seemed to have rectified the cause. Hence, faults are still present on the GSA.

I'd welcome other suggestions, if there are anymore, especially those, that had not been taken up yet. I'm almost convinced that the mod's control unit is the cause of the problem, probably incorrect values, voltage or signals, since the GSA's motor, worked perfectly well on the 12GS.

Anybody encountered anything like this out there?

Thanks again everyone!

Bernard R.


 


     
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on February 06, 2014, 02:56:34 AM
Bernard

I have a early 2008 GSA with the same two fault codes (24048 and 24049).
Interested to know if the fault occurred on your bike at a specific time.

For example - I have been doing a full service on the bike - new rear brake pads, new brake fluid front and rear etc and then when I take it out to test ride - ABS fault.

Now the bike had to sit for two months prior to this as it had fallen over and I hurt my back trying to stop the inevitable. My mate rode the bike the 50km home for me but he maintains he did not see the ABS fault light on - he has an R1150RS and I am sure he would have noticed the light if it had been on.

So I understand the fault message and realise that it probably means the motor brushes are sticking - but is it a coincident or is it something stupid I have overlooked.

Battery is in good condition - lives on the BMW trickle charger - when bike is not being used. Mileage is about 34,000km.

So interested in what has happened on your GSA.


Regards


Mal
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on February 21, 2014, 10:24:58 PM
Bernard

While I assume you are no longer reading this thread, for others who do read the thread here is my ongoing issue.

When I took the armature to the local specialist electrical repair company they found it had shorts in the windings.
So basically, it is not the brushes, it is a shorted out armature.

When I checked the pump pins, the small pins in the aluminium block that the electric motor push in and out, one was seized up and the other hard to actuate.

I am now assuming that the reason for the pump failure is the seized up pump to the rear brake side of the ABS unit. Because I can see no easy way to refurbish this seized pump, I have ordered a new ABS unit complete.

The part that still bothers me is how to prevent this part of the ABS failing so quickly next time.
The bike is a 2008 model with 34,000km.

Perhaps this is the answer, well this is what I am thinking.
1. While the brake fluid has been changed every two years, this may not be often enough if the bike is not being used regularly. I now intend to change the brake fluid every year.
2. The bike is not being ridden regularly - we tend to do long trips now and then rather than riding every week. I now intend to ride the bike on a regular basis - say once a week.
3. This is the tricky bit. How does the pump body get fresh brake fluid flushed through it on a regular basis?
I have seen people say, this is what happens with the initialisation  process - if so, why has my pump frozen up?
Others have said you may need to actuate the ABS in a user situation by locking the brakes - this seems rather extreme, to push a safety feature that is meant to be a safety net, just to keep it operational - but maybe it is true.
Finally I have wondered if the GS911 will actuate the pump and flush the brake fluid, but I have the bike in pieces at present so will wait till all is together before reconnecting the gs911 and seeing if any such option exists.

So the message here is - CHECK the ARMATURE and the PUMP PINS.



Mal
Australia
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Haakon on February 21, 2014, 11:56:17 PM
My stupid input here: (I fully understand its not fun to provoke the ABS to "kick in"- except for silly people like me :-))
Why not use the GS911`s ABS bleed function when you change your brake fluid?
OR use that function more often?
The ABS units valves, pumps and motor will last longer if they "run" a bit.
Not so much because of the brake fluid than to make the parts "move".
I can not think of ANY man made  "mechanical" gadget that benefit from not to be used.
Oil and grease go rancid and harden, corrosion build up and so on.
Provoke the ABS to kick in once a while (to make sure it works WHEN you need it)
OR use the GS911 to do a ABS bleed- then all the valves and motors are working.
I provoke MY ABS to kick in ever so often- and LOVE that .
It cost a bit in new brake pads but....
Haakon


Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: bikecrazy5 on February 25, 2014, 12:45:02 AM
hi guys
i agree totally with haakon... :o believe it or not i provoke my abs ever so often...knowing they way i ride some or other time i will need the abs and i would really prey and hope it works

the bleed test on the gs911 is a brilliant substitute to being a nutter ;D
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on February 25, 2014, 03:28:28 AM
The question I have is, does the GS911 offer a "run ABS pump function" for the 2008 and later model ABS units.
It is clear this option is available for 2007 ABS 1 units but not sure about the ABS 2 units.

It would be really stupid if the ABS 2 pump could not be flushed during the routine service and only relied on being activated while riding the bike.

A safety net system that has to be fallen into to check it works - like setting fire to your kitchen once a month so you can operate the fire extinguisher to keep it operational. Well maybe a bit extreme - but it would still be stupid in my estimation.


Mal
Title: run ABS pump function
Post by: marchyman on February 25, 2014, 06:25:03 AM
The function chart -- http://www.hexcode.co.za/products/gs-911/function-chart/ -- separates iABS-CAN and iABS2-CAN.   The former are the whizzy brakes, the latter are the brakes found in '07 and later bikes.   Is "Service functionality" listed as yes for your bike in the iABS2-CAN row?   I think that's what you're looking for.

On the iABS (whizzy brake) bikes it's not a run ABS test.  It's a turn off the ABS pump and check that the ABS pressure is OK when pulling the lever test.  I haven't run the test on an '07 or later bike to know exactly what it does.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on February 25, 2014, 07:12:28 AM
well my new ABS2 unit has arrived at my dealer and I should have it in 48 hours - then I guess I will find out when I put it all back together.

Thanks for your help.


Mal
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on February 25, 2014, 08:05:08 AM
The iABS and iABS2 pumps operate completely differently.

The iABS (Servo assisted) pumps have closed off chambers containing fluid.  Thus the need for the bleed function.  What that in essence does is opens the valves manually to allow the fluid to flow through the chambers.

The iABS2 pumps have no such chambers and bleeding can just be done in the conventional way, as all the fluid in the pump gets flushed out.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on February 26, 2014, 04:59:10 AM
Jughead

Thank you for your reply.

There are lots of things I don't understand and at least some of them relate to this ABS unit.

If the fluid gets flushed out when the brake fluid is changed how come, now I have my pump partially disassembled, when I pour brake fluid into the intake side of the pump and for that either side of the pump, and I then actuate the pump pins by hand, the brake fluid does not rise or fall, suggesting that the pump is only connected to the brake line when a solenoid is activated.

I therefore am assuming that either the solenoid that is supposed to remain open at its not powered position is stuck shut, or there is some other explanation that you may know.

Also at present I am assuming that the only time the pump is activated is either when the respective wheel locks up and the pump takes part in the anti locking process or when the bike is started and the initialisation process takes place (but this is just wishful thinking).

Any help understanding the workings of this system would be appreciated.


Mal
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on February 26, 2014, 07:45:07 AM
Hi Mal

As stated in my previous post, the iABS and iABS pumps operate differently.

As I understand it from dismantling an iABS2 pump, it does not actually pump fluid.  The 2 pins that are actuated by the motor cam are the ends of valves that merely interrupt and release the pressure in the two circuits when activated, in this way alternately preventing the wheels from locking up.  I will see whether I still have the remains of the dismantled unit to show what I am referring to.

If you had to remove the front calliper pipe the fluid would(should) flow freely from the reservoir, through the pump, and out the end of the pipe until the reservoir and pump is empty.

The iABS (Servo Assisted) pumps are different in that they actually pump fluid to assist with braking, and at the same time shut off when wheel speed differences are detected.  Disconnecting the calliper pipe does not empty the reservoir.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on February 26, 2014, 08:22:19 AM
Hi Jughead

It is always fascinating to find out one has made a major assumption which completely undermines a correct understanding of the situation.
I did assume this was a pumping device.

So what are all those solenoids doing?

I Haven't pulled the pump/aluminium block apart to try and understand this but I think I will as soon as I have some more time.

Obviously would appreciate any light you can throw on the matter.



Mal
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on March 05, 2014, 10:31:44 AM
Ok Malmac, found the valve.

The first pic is the complete valve, the end of which is indicated by the arrows in your pic above.

The second pic is the valve which has been dismantled.

The third pic is a closed-up of the shuttle part of the valve.  The 2 bypass holes can be clearly seen.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: mike d on March 05, 2014, 11:24:55 AM
Good Photo's!

Any experience of those small filters getting clogged and thus causing ABS failure?

MIke
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on March 05, 2014, 11:27:53 AM
No, as long as the fluid id replaced at the regular intervals.

I replace fluid with every 10 000km service or annually.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on March 06, 2014, 10:39:10 AM
Jughead

Your willingness to share information is a great asset to myself and others on the forum.

My project to date is -

I have fitted my brand new ABS unit.

Have bled both front and rear brake circuits - BUT still not happy I have all the air out of the front circuit.

I have yet to dismantle my pump and see why it has frozen up.

I note your advice about changing the brake fluid often - I was doing it every two years but it will now become an annual event.

Will keep everyone updated on anything I learn.


Mal
Australia
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on March 06, 2014, 10:57:02 AM
Hi Mal

Bleeding the front calipers can be a real PITA when they get air in them.

Try this:

Once you have bled the system in the normal way, remove the callipers from the forks and allow them to dangle free.

Remove the brake pads, or at least one of them.  You are going to want the piston in the calliper to be pushed out as far as is possible without it dropping out of the calliper.  Stop them from falling out with a suitable spacer.  One pad usually does the trick.

Exercise the brake lever and push the pistons out as far as they will go.  Holding the calliper at about a 60deg angle with the bleed nipple uppermost, open the bleed nipple and slowly force first the lower piston back into the calliper.  Once it is all the way in, force the upper piston back in as well.  You will possibly find a lot of air coming out.  Repeat with the other calliper.

Replace the pads, bolt the callipers back in place and refill the brake fluid reservoirs as you pump the lever to get the pistons out to their normal position again.

Hope this makes sense.  Will try to get some pics for you that will make it easier to understand.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on March 06, 2014, 12:09:27 PM
OK, here is a bit of a crude drawing to show what I am talking about.

Brake fluid is forced into chambers "A" and "B".  While the upper chamber has 2 holes, one for fluid and one for air, the lower chamber only has 1.  So fluid enters the chamber following the blue arrows, but the air trying to follow the yellow arrows gets trapped in chamber "A".

Tilting the calliper (as in the second pic) and forcing the piston back, forces the air out of the chamber.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: malmac on March 06, 2014, 01:18:47 PM
Jughead

You seem to be onto something here. I will experiment with this and let you know how I get on.

I have been focussed on the ABS unit - the calipers may well be more than half the problem.


Thanks again.


mal
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Joe-T on April 26, 2018, 12:44:06 AM
OK, here is a bit of a crude drawing to show what I am talking about.

Brake fluid is forced into chambers "A" and "B".  While the upper chamber has 2 holes, one for fluid and one for air, the lower chamber only has 1.  So fluid enters the chamber following the blue arrows, but the air trying to follow the yellow arrows gets trapped in chamber "A".

Tilting the calliper (as in the second pic) and forcing the piston back, forces the air out of the chamber.

Hello Jughead,
thanks for sharing your knowledge. Although not quite a recent posting I hope you would read this.

As the R1200GS calipers do have four pistons I actually can't make 100% sense of your schematic drawing. To me this looks like a two piston caliper and I can't get this fit with my 4 piston caliper.
Mentioned 60 degree tilting may work for the outer pistons but it's sub-optimal for the inside pistons. (Without dismanteling the caliper I dont actually know which internal channels exist.)

Would you be able to bring some light onto this sub-topic.

Thanks, Joe-7
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Jughead on April 26, 2018, 07:18:07 AM
Hi Joe-7, and welcome.

The schematic I posted is just that, a schematic to illustrate where the air is trapped and how to resolve the issue.  By no means is it an accurate drawing of the R1200GS caliper.  It is in fact roughly only half of the caliper but the same principals apply.

Be that as it may, take the schematic and make a mirror image of it, then put my schematic and the mirror image together and you have roughly what the R1200GS caliper looks like, with the exception of the brake pipe and bleed nipple.  Once again, not 100% accurate in every detail.

What I suggest is the following:

Remove the caliper from the fork and remove the brake pads.  Insert a wooden block in place of the brake pads that will allow the pistons enough travel without falling out altogether.

Fill the reservoir with new clean brake fluid.  Activate the front brake lever, pushing fluid to the pistons to the point where they are making contact with the wooden block.  Open the bleed nipple and starting from the lower piston furthest away from the bleed nipple, tilt the caliper as illustrated for the relevant side, and push the piston back into the bore as far as it will go.  Now do the same with the piston above it.  Repeat with the 2 pistons on the side with the nipple, once again first the lower one, then the one closest to the nipple.  Close the nipple.

Repeat this process for as many times as it takes for you to be able to push the pistons back without any air escaping from the bleed nipple.
Title: Re: Integral ABS 2 - CAN "Power Supply to Pump motor faulty"
Post by: Joe-T on April 26, 2018, 02:43:40 PM
Thanks Jughead for this clarification!

I think I've got it now. So the tilting direction changes when pushing the inside or outside pistons back in.

Joe-7

P.S.
One word of a warning to anyone working on this:

While pushing the pistons back in watch out for the other 3 pistons which tend to get pushed out during this step. I accidentally got one piston far enough to fall out. ... Now I definitely had enough air in the system ...
It may help to use two smaller wooden blocks - one between the lower - one between the upper pistons to reduce this risk. Leave the upper block in place while starting to push the lower pistons back in.