ABS light issues

[talonboy]

Howdy all, just wanted to post this as a record, to possibly help others with ABS issues. My issue started when I replaced the front tire, front turn signals with aftermarket LED units, and signal flasher for LED. I immediately left for 2500 mile trip. I had the ABS light on most of the time. I figured it was the smaller size front tire I installed. Upon returning home again, I purchased and installed the correct size tire. ABS light remained on most of the time. Finally spent some time reading thru post here of people with ABS issues. Thanks to all the posters for the help. I read the codes from the bike, had at least codes 11, 12, 25 and 33. Cleared the codes. Tested on several sort rides, less than 5 miles. Light remained on much of the time. Read codes again, no codes to be found. Found a post that mentioned LED lights being a possible issue, disconnected my LED turn signals, unplugged new flasher. Several short test rides, ABS light on much of the time. Read codes again, none found. Finally today was able to ride a bit further. Noticed the ABS light would be on, but go off if I pulled in the clutch and coasted at various speeds. Let the clutch back out, ABS light comes on again. Every time. Here is a really strange situation, going 40-60mph ABS light on solid, pull in the clutch, let off throttle ABS light goes out. Rev the engine with clutch pulled in, ABS light comes on every time I get over 2500 rpm, and goes out below that. Let clutch out, light comes back on. Continue to ride to my destination about 20 miles away, notice light blinking off occasionally, then back on. Then light goes off for a mile or so, then back on. Then off again. Finally stays off. Several stop signs, light is still off. Stopped to shop for a few minutes, started bike and returned 20 miles home. Light off whole way.

Just documenting my thoughts. So LED turn signal lights still disconnected, deciding on whether to hook them up again or test further disconnected. I had installed LED head light bulbs, aftermarket LED light bar, and LED license plate light several years ago. None of these caused an ABS issue once. One stock turn signal rubber ripped, creating the reason to change signals, so I can't easily hook the stock ones back up at the moment. Going thru service manual test steps, it suggested replacing the gauge cluster as a solution? I didn't see anything that mentioned riding the bike 20 miles to see if that would reset the ABS settings. 2012 Tenere, 55k miles. Never had an issue with ABS before. Had switch rigged up to turn off ABS, disconnected that, and returned to stock setup. Had checked the front and rear wheel sensors, they were clean. Battery voltage seems normal, stock lead battery. Disconnected battery and cleaned terminals, no change. No idea what tripped the ABS issue in the first place.

 

[WJBertrand]

You mentioned changing the front tire. I would get down on the ground and carefully examine the sensor wiring condition and routing. There's a little wire bail down on the left fork that keeps the cable clear of the brake disk. If not routed correctly the disk can saw into the cable. Also check that the sensor is not loose in the hub cover and that the cover is properly interlocked and positioned with the tab on the inside of the lower left leg. I'm betting somethings not quite correct in the reassembly or the sensor was damaged.
I doubt the LED indicators have anything to do with this issue and you have verified that my disconnecting them to no avail.

 

[talonboy]

Jeff,
Thank you for the suggestions. I have looked over the wiring to the front sensor, and don't see anything wrong. I have removed both front and rear sensors, cleaned, and reinstalled several times. The front hub cover appears to be locked in correctly, as it was with other tire. Of course I could be wrong.

I tested again today, ABS light came on immediately, and stayed on most of the time up to around 10 miles. Found like yesterday, at rpm below 2100 light is off, clutch in or out. Above that rpm, light is on until about 4500 rpm, then light would go out. Hard to keep it above 4500 rpm except lower gears. Rode about 10 miles trying to keep the light off as best I could. Over time up to around 10 miles, light was on. After about 10 miles, light was randomly turn off, then on. Eventually staying off under any condition for 5 miles or so until home.

Looked at the non-stock tire I installed previously, it was a 100/90-19, pretty close to stock 110/80 tire diameter.

 

[talonboy]

Test again tonight. LED turn signals reconnected. Tonight was a bit cooler than the last couple daytime tests. ABS light very similar to previous two tests, except it took a few more miles before it went off completely. Maybe it is temperature related? It takes the ECU 10 minutes to warm up and start working correctly? The LED lights may have nothing to do with the issue.

 

[WJBertrand]

The sensitivity to RPM makes me think there’s a loose connection that’s sensitive to changing vibration? It does not take the ECU 10 minutes to warm up. It should be working fully immediately.

 

[Mr. BR]

I wonder if your slightly larger front tire size is a factor? (100/90 vs stock 110/80).
Otherwise, seems like checking for loose connections as stated above is a good idea and perhaps monitoring your system voltage while riding.
Have you pulled the large harness connector on the pump unit just to ensure it is clean/dry? That area can get dirty if it doesn’t drain correctly.
Just FYI: my ’12 with 85K miles has the ABS light always ON and I bought it this way 1.5 yrs ago. My error codes are front sensor (11, 25) and ABS motor shorted/defective (33, 34).
I’ve spent a few hours going through my Yam shop manual checking voltages, continuity, grounds etc and I’ve replaced the front sensor, cleared codes but light still ON (I haven’t rechecked codes yet but I expect front sensor error is gone). Manually exercising the pump gets me a few clicks and movement at the front brake lever but the ABS pump motor is clearly not running (I may remove it/bypass it but I would prefer to have it working correctly).
Anyway, good luck moving forward!
Regards,
Mr. BR

 

[talonboy]

Mr. BR, I thought the different size front tire was the source of all my issues, as the ABS light came on right after I installed it. I had checked the wiring, and the front sensor at the time, but found no issues there. I rode the bike 3k plus miles with that tire, ABS light on most of the time. I finally bought the correct size tire 110/80 Shinko, and compared it to the100/90 Heidenau I just removed, they where pretty similar height placed side by side. The bike did steer lighter with that tire, but it was the only Heidenau I have ever used on the front. Once I installed the new tire and ABS light was still on, that is when I started looking thru the forum here and service manual for ideas. I learned the process to read the codes, reset the codes, and spin the ABS pump. All of those worked. I got the codes, listed above. I cleared the codes, none have ever returned, even though I have the ABS light on. I have spun the ABS pump ,3-4 times, I can feel it thru the levers. I haven't had the opportunity to ride the bike very far yet, just test rides to see if ABS light will go out.

I tried to get to the ABS pump and see if I could unplug and check the connection, but wasn't able to get my hands on the connector easily. I removed the plastic cover over the top so I could see the ABS pump, but that didn't give me good access to the connector. I didn't didn't really try very hard, didn't consult the manual for listed process. I plan to do that when I have free time. As Jeff pointed out earlier, maybe there is a loose connection that is effected by engine vibration? The connector on the pump was were I was going to start.

 

[scott123007]

So, if I understand your last post correctly, you are saying that the ABS still functions normally even when the light is on? (I'm guessing that's what you mean by "spinning" the pump, but I have never heard it called that) I was going to suggest checking the 30A ABS fuse to see if it had a intermittent connection, but if your ABS is working as it should, regardless of what the light is doing, it can't be that.

 

[Jlq1969]

Maybe I'm saying something stupid, but starting from the base of the problem started after disarming the front wheel.... What possibility is there that you armed the wheel in a wrong position???? (with the phonic plate on the other side)……I don't know if it is possible

 

[simmons1]

Make sure you didn't bend the mount for the sensor or damage the ABS ring on the wheel itself.

 

[talonboy]

So, if I understand your last post correctly, you are saying that the ABS still functions normally even when the light is on? (I'm guessing that's what you mean by "spinning" the pump, but I have never heard it called that) I was going to suggest checking the 30A ABS fuse to see if it had a intermittent connection, but if your ABS is working as it should, regardless of what the light is doing, it can't be that.

The ABS functions normally if the light is off, the ABS does not work if the light is on. Even if the light is going on/off frequently, the ABS works when light is off, moments later light is on, ABS does not work(rear wheel will lock). spinning the pump is a term I read here, a process to make the pump activate at standstill for testing.

 

[talonboy]

Maybe I'm saying something stupid, but starting from the base of the problem started after disarming the front wheel.... What possibility is there that you armed the wheel in a wrong position???? (with the phonic plate on the other side)……I don't know if it is possible

I am pretty sure you can't mount the front wheel backward, the ABS hub only goes in one side of the wheel.

 

[scott123007]

The ABS functions normally if the light is off, the ABS does not work if the light is on. Even if the light is going on/off frequently, the ABS works when light is off, moments later light is on, ABS does not work(rear wheel will lock). spinning the pump is a term I read here, a process to make the pump activate at standstill for testing.

If that is the case, then there is a possibility that the fuse, or something in that vicinity may have a bad connection. I read in your first post that you had a setup to disable your ABS, and that you have since disconnected that to no avail, but since I don't know what you did to disconnect it, I'm just throwing out there the possibility of there being a bad connection in the fuse area.
It does seem suspect though, that the problem started after the removal of the front wheel, but I can't think of anything else that others haven't already suggested.

 

[talonboy]

If that is the case, then there is a possibility that the fuse, or something in that vicinity may have a bad connection. I read in your first post that you had a setup to disable your ABS, and that you have since disconnected that to no avail, but since I don't know what you did to disconnect it, I'm just throwing out there the possibility of there being a bad connection in the fuse area.
It does seem suspect though, that the problem started after the removal of the front wheel, but I can't think of anything else that others haven't already suggested.

I had the ABS fuse jumpered with two wires with spade connectors to a on/off switch. I reinstalled the stock fuse, so it's back to stock.

 

[talonboy]

Thanks for the feedback guys, I do appreciate it. I have owned this bike since 2013. I have have changed all the tires myself, as well as all other work.
Rode to work this morning, temp 52 degrees. ABS light was on pretty steady about 15 miles, then blinking off/on for another 10, then off the rest of the way. Stopped for gas, shut bike off. Restarted, light still off last mile. Which make me think it is temperature related, as it took much further to go off than at warmer temps. When I ride the bike long enough that the light goes out, I can shut the bike off, at when restarted light is off. When sitting overnight, light was off when parked, light is always back on immediately next day. So something temperature and vibration related? But what?

 

[Jlq1969]

Thanks for the feedback guys, I do appreciate it. I have owned this bike since 2013. I have have changed all the tires myself, as well as all other work.
Rode to work this morning, temp 52 degrees. ABS light was on pretty steady about 15 miles, then blinking off/on for another 10, then off the rest of the way. Stopped for gas, shut bike off. Restarted, light still off last mile. Which make me think it is temperature related, as it took much further to go off than at warmer temps. When I ride the bike long enough that the light goes out, I can shut the bike off, at when restarted light is off. When sitting overnight, light was off when parked, light is always back on immediately next day. So something temperature and vibration related? But what?

The strange thing about all this is that, once the abs light comes on (for whatever reason, a fault or a manual disconnection)...this light stays on until the ignition key is cycled and the fault disappeared or manual disconnection occurs.
You talk about temperature and light on/off, but why not think that the light "is always on" (due to a fault or disconnection) and that when the LED gets hot, it turns off due to bad contact?.
Maybe you have a permanent ABS fault…and a faulty LED indicator too.

 

[scott123007]

The strange thing about all this is that, once the abs light comes on (for whatever reason, a fault or a manual disconnection)...this light stays on until the ignition key is cycled and the fault disappeared or manual disconnection occurs.
You talk about temperature and light on/off, but why not think that the light "is always on" (due to a fault or disconnection) and that when the LED gets hot, it turns off due to bad contact?.
Maybe you have a permanent ABS fault…and a faulty LED indicator too.

@Jiq -- He stated that when the light goes off the ABS works, so it is not a permanent ABS fault.

 

[talonboy]

@Jiq -- He stated that when the light goes off the ABS works, so it is not a permanent ABS fault.

Correct. ABS works correctly, based on the light being off or on. I have no codes for the ABS, the last 10 times I have checked. Once the ABS light goes off, everything is normal. After enough time/distance light doesn't come back on, ABS works as it should. The light isn't ever always on, it only comes on once the bike is moving. At a stop the light is off. Riding in first gear at idle light is off. In 6th gear below about 40mph the light is off. Only when I get above around 2k rpm moving does the light come on. I haven't tested stopped, revving the engine.
It's hard to believe I am the only one that has had this issue in the length of time the bike has been out.

 

[Jlq1969]

I have not read anything similar before. But if it started after disassembling the front wheel, the problem must be somewhere nearby. In the ss manual, they are very demanding when it comes to the sensor and phonic plate... it may not be warped, they require measuring the warpage and if it exceeds a range, changing the phonic plate

 

[talonboy]

I have not read anything similar before. But if it started after disassembling the front wheel, the problem must be somewhere nearby. In the ss manual, they are very demanding when it comes to the sensor and phonic plate... it may not be warped, they require measuring the warpage and if it exceeds a range, changing the phonic plate

My problem did start after removing front wheel, and removing headlights for turn signal change. Interesting note about warpage, I hadn't seen that in service manual, I need to look that up and see the process.