BMW R1200GS brake-fluid funnel for servo

I required a tool to help flush the brake-fluid in my 2005 BMW R1200GS, without introducing air into the servo-assisted circuits. And I did not want to spend lots of money and time waiting for it to arrive. As far as I know, this funnel should fit most of BMW R and K-models from 2002-2007, that are outfitted with servo-assisted brakes.

It may not directly fit some models other than the R1200GS, but that should be pretty easy to fix, by only printing the lower, narrower part, and using some DOT 4 resistant sealant to fit a taller funnel to it

If you want to make an improved version, the thread used is M18x2.5mm.

This is not the actual model I made for myself, but a slightly improved one, that is a bit taller, with thicker walls, and a larger volume.

BE VERY AWARE, THAT IF YOU DO NOT HAVE A SOLID UNDERSTANDING OF HOW THE SERVO-ASSIST SYSTEM WORKS; YOU SHOULD NOT ATTEMPT TO DO IT YOURSELF.

ALSO, BE AWARE THAT ANY DEBRIS INTRODUCED INTO THE SYSTEM, OR SIMPLY FAILURE TO MAINTAIN THE BRAKE-SYSTEM, MAY RENDER THE BRAKES INOPERABLE, OR EVEN LOCK THEM UP AT SPEED.

WHEN THEY WORK PROPERLY, THEY ARE INCREDIBLY EFFECTIVE, BUT THEY ARE ALSO KNOWN FOR THEIR POTENTIALLY LETHAL MODES OF MALFUNCTION.

USE THIS TOOL ON YOUR OWN RISK!

How to do the job (not my videos):

Video 1:

www.youtube.com/watch?v=YLM25NYvlas

Video 2:

www.youtube.com/watch?v=a1ktxY_bgQY

(Sorry for disabling the links, but they killed the pictures.)

Print Settings

Printer:

FLSun QQ-S PRO

Resolution: 

200

Infill:

30

Filament:

Generic PETG

Notes:

Must use PETG, as brake fluid dissolves ABS and PLA.

To avoid leaks, print at high temperature (i used 250C), use a wider extrusion width (I used 0.55mm with 0.4 nozzle), and use as low amount of cooling as you can.

Layer-height 0.2 - 0.3

Use a 17x2.5mm o-ring (or whatever you have that can make a proper seal. Remember that brake-fluid may destroy the o-rings in a very short time, depending on material...

Post-Printing

Clean it up well, make sure there is nothing that can come loose and fall into your servo-pump.

I used a lighter to sear any stringing.

Before use, I cleaned it with some brake-fluid. As it should absorb any water in the PETG.

Category: Automotive