I've reviewed many of the ABS threads and found that most end up dead ended with no report on what the problem was. I'm hoping I can get some help here with my issue.

I flushed my brake fluid using speed bleeders and am very confident I have not introduced any air into the system.
I then installed some new custom wheels that came with the ABS bearings pre-installed, replaced the brake pads and now my ABS light stays flashing.

I have verified twice now that the bearings are installed with the green side facing out and are on the correct side of the wheel. I have also verified my sensors are installed correctly.

When I unplug each sensor one at a time the light stays on solid, and returns to flashing when plugged back in. This tells me the ABS module is recognizing them.

When I check for fault codes using my SEPST, there are none showing.

I hate the thought of taking it to the dealer to have them mess around with it to the tune of several hundred dollars.

Any thoughts?

 

Very difficult to say and I am by no means anything like an expert.

I do design and commission complex control systems. If I were to speculate (stress speculate) I would suggest it is more likely related to your flushing / bleeding process.

If the fault is showing up during initialisation and before the bike is moving then I can't think how it could be detecting a faulty bearing (although in this case the bearing case is working as part of your feedback device).

The bearing, together with the sensor, provide speed feedback for the control system, where rate of change of speed is used to detect a lockup. If the bike hasn't moved yet then how can a check take place? Removing the sensor can trigger an error as there is no surface that it can reflect off of.

If the system was showing as healthy but then alarming as soon as you set off then I would suspect the bearing.

Again, I must stress, this is total speculation

 

When I ride the bike the light remains flashing. It normally clears after you have travelled a short distance and the system checks that the signals are rational.

I am wondering if one of the bearings is bad?
Does anyone know how to check?

The brakes work perfectly and are not the least bit spongy.
I am confident there is no air in the system.
Even if there was, I don't know how the ABS module would know.

 

I hate ABS that give issue like this. It really should be simple. But due to electronics (if A don't like B) Your Forked.

I disable my ABS when they act-up but on cages. My old ride never had them.

 

There is a specific procedure to follow, you can not skip any of the steps.
Check your service manual.
I had a problem when I replaced the rear brakes and found one of the plugs were unplugged. had to take it to the dealer, I don't have a service manual yet. it cost me $25 and 1.5 hours waiting time.

 

You said:
"I have verified twice now that the bearings are installed with the green side facing out and are on the correct side of the wheel. I have also verified my sensors are installed correctly."

The HD ABS bearings on my bike have an orange seal on one side and it faces inward. Part # 9252

I take it you don't have HD ABS bearing? If so that would be your problem.

 

you might try to disconnect the bat. to see if that will clear the codes then see if they come back

 

I'm betting the installed bearing isn't an ABS bearing. Orange on one side, green on the other, line going around the outside of the bearing, 3mm from the edge.

Reinstall the wheels you know worked, then you'll know if it's the bearing. If it's not that, then I'd take a hard look at the sensors. It's really a simple system, there's not much to go wrong. You may also look at whether the new wheels turn at the same rate. Wheels of dissimilar size will spin at different rates keeping the ABS from setting up initially. Compare the wheel size and tire size/aspect ratios. A larger front wheel will turn less than a smaller rear wheel provided an aspect ratio adjustment doesn't reconcile the overall diameter of the two wheels.

 

The flashing ABS light is normal until you start rolling. After a short distance it will go out if everything is normal. Mine does it every time I go for a ride.

How "short" is the distance? It should be very short. I think the light is set to go off at around 3 mph (don't quote me on that).

Is ABS working normally? Stomp the rear or grab a handful of front lever to check it but don't go very fast to do the check.

Once the light goes out does it stay out for the whole ride?

Sounds normal to me.

 

If the ABS light doesn't go out at 5mph, it's inactive. Only regular braking is available and there is a fault in the system.