ER-6N ABS -error code 19

Bought a used kawasaki -2007, got a pricereduction due to a
ABS error.
Luck would have it that the service manual was easily available.

Initial investigation

Performed the fault code readout. you have to ground a white connector underneath the seat and then turn the key to ignition pos.

Table from service manual

It gave me code "19". I performed the reset procedure hoping it would be intermittent, but it was not, code returned as soon as i started the bike and rolled a few meters.

"ABS solenoid valve relay trouble (wiring shorted or open, stuck relay (ON or OFF) or dropout)"
-this could mean anything...

Fuses were all ok, for every system -no corrosion or poor connections to be found.

"Fixing" the problem

"fault finder".

Gave the ABS unit a light nudge with a rubber hammer, and then reset the fault code again.
The ABS unit did not light the fault led any longer and braking on gravel actually worked, wheels did not lock up.

This slightly narrows the errors down to internal unit issues or power delivery.

Teardown

First of all remove fuel pump fuse and open the fuel tank filler cap,
start the bike and let it run out of fuel.
This will remove all pressure from the tank/hose.
This must be done before any work is started.

Unbolt the fueltank

Remove side trim, left and right, three rubber mounts

A good tip, insert and keep in place a zip tie
helps with removal/ insertion of battery
also prevents the little square nut from falling out.

Fuel tank has safety valve so it will not leak when removed.
lift and then disconnect the 4 pos connector and undo the clip for the hose while it is still hooked on the the front rubber mounts.

Fuel tank removed, protect the fuel hose with cloth,
store the tank safely away from heat and sparks.

Remove ECU

Unhook brake reservoar.

Remove the battery tray.

ABS cable harnes removed, poorly photographed.

Fixing the issue

It's quite obvious the problem is oxidation of the terminals.
thorough cleaning with oxide clenaner and scraping the therminals free from gunk and debris.

Excellent tools, available at you local pet store

Two middle pins are 12V feed from fuses.
Also some melting visible.

After cleaning a coat of terminal protection was sprayed on.

Products used

Assembly in reverse order of course ; P

Additional fixes

Fuel tank mount

One rubber mount was missing for the fuel tank

Only one left...

Printed a new one, TPU, shore hardness A95

Thingiverse for *.STL file

Air filter

Recommend removing the screws so that there
is less risk of breaking the hose mount.

Foam type filter, after some vacuum cleaning I soaked it in brake cleaner and washed it with luke warm water and let it dry.
it was good to go again.

Final words

-20200716

So far the ABS light is still off during riding.

-20200802

As of approx. 1000km (600 miles) of riding, still no issues.

-20201004

Bike was taken for final ride before put into winter storage
and as of approx. 2000km (1200 miles) of riding, still no issues.

-20211008

Bike was put into winter storage, still no issues