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Fixed a stuck ESA rear shock (preload) on 2005 K1200S

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MikeSF:
I know that this post is now quite old, but it does have a lot of relevant information for someone that is experiencing ESA problems. I too have been suffering them on my 2007 K1200R. When I first purchased the bike the ESA button functioned as normal and the stepper motors on the front and rear all worked as they should do. The only thing that did not work was the preload adjuster. I went to CW Motors of Dorchester and they advised me that sometimes the rear ESA preload jams but you can apply 12volts directly to the blue connector and sometimes get things moving again. Following this you will need to have the device calibrated. I went away and did as they suggested and the ESA preload would go through the routine fine. I then got in touch with someone who had a GS-911 and asked them if they would calibrate the ESA. He was aware that the software was not designed for the ESA with potentiometers (just Hall Effect type) but was prepared to give it a go by doing as Trickflow has suggested.

After trying the routine several times we conceded that it wasn't going to be fixed. What I hadn't anticipated was that after connecting and running the routine my ESA button and associated display Icons had completely malfunctioned.

The purpose of my post was to give everyone the background to my problem and then some information that I was given when I returned to CW of Dorchester to get them to try and calibrated the ESA.

CW tried the calibration but their diagnostic system reported that there was a wiring issue. It wasn't very specific and as such CW recommended that I book the bike in for further checks. Like so many other owners I did not want to rack up a bill only to find that this was going to cost a fortune to fix. CW were quite understanding so I asked asked them what I could do as far as second hand replacements were concerned, i.e. if I had to replace the ZFE. They advised that in the past they would be able to connect to the BMW diagnotics and reconfigure the unit to run, however the situation has now changed such that BMW will not allow a second hand control board to be fitted. CE also advised that if anyone does this then there is a possibility that the unit will work fine providing all else is okay, but should be aware there are consequences. If you take your bike and subsequently plug it into the BMW diagnostic system it will render the control board inactive. There was also an indication that other boards could be affected in that the diagnostic system would write a new serial number to other boards and that they too would be rendered inoperative. This all sounded so outrageous to me but thought that perhaps BMW might justify this by saying it stops people stealing bikes to sell the parts. Whatever the reason, it has given me the incentive to buy a ZZR1400. I still have not given up on the K1200R, but am really frustrated that BMW's cost so much to maintain, and compared to my experience of Japanese bikes BMW are far more unreliable. 

Old goat:
I gave up with the ESA, not wanting to waste any more money on the problem. I bought a pair of second-hand non-ESA suspension units in lovely condition and at reasonable cost and removed the ESA switch from the handlebars. I'm perfectly happy with the bike as it is. Would I like to have working ESA, well yes, but not at any price on a 10-year old bike.

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