1200GS Dead In The Water

Discussion in 'GS Boxers' started by Chat Lunatique, Jul 29, 2012.

  1. Chat Lunatique

    Chat Lunatique aka El Gato Loco

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    Guys... A 2010 R1200GS on an extended tour of the Midwest and southern US died in the rain on the Blue ridge Parkway coming home to Canada. In a severe thunderstorm with heavy rain, on top of a mountain, in the middle of nowhere, the engine started to violently backfire, vibrate and pre-detonate. I immediately pulled over and rolled off the throttle. The bike purred at idle. As soon as I moved the throttle off the TB stops, the misfiring reappeared. As lightning was striking too close to me with no shelter,I had to ride it off the mountain in second gear at an idle. After a few minutes the engine was slowly able to take a little gas and returned to normal after 20 mins of bucking.I pulled into a great motel called Freebornes in Laurel Springs where all the Harley guys had pulled off. They got me in touch with a BMW dealer and I rode there the next morning. The tech said that it was the fuel pump controller and put a new one in. When I asked why he didn't run the codes first he said this problem was so common, he didn't need to. When he ran the codes after installation, sure enough 27B7 electric fuel pump came up and was cleared. He recommended that I carry a spare fuel pump controller on future long trips as this failure was common.

    My question to my fellow inmates is this. I thought the fuel pump controller issue had been put to bed a few years ago. Can anyone give me some feedback on late model fuel pump controller failures? Thanks!!!
    #1
  2. bemiiten

    bemiiten League of Adventures

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    Did the tech say anything about it getting wet? On the Adventure the controller sits in a cup that holds water, so having the seal installed properly is critical. Big thread over at UKGSer.com on these, but hasn't been much rumbling about them here for a while.
    #2
  3. Wolfgang55

    Wolfgang55 Long timer

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    Where is this thing located, some may care to check to see the seal is sealing, much thanks.

    As I read this, it maybe a seal issue...............?
    #3
  4. bemiiten

    bemiiten League of Adventures

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    Top left of the tank on the Adventure. I beleive LH side of tank on the STD. GS
    #4
  5. PARIAH

    PARIAH Been here awhile

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    One more thing to worry about.
    #5
  6. lhendrik

    lhendrik Truffle Rustler

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    Don't ride in the rain on a GS
    #6
  7. LaurelPerryOnLand

    LaurelPerryOnLand Long timer

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    "On BMW R1200GS, R1200GS Adventure, R1200RT, R1200ST, R1200R, F800GS and F650GS-twin motorcycles, the fuel pump controller can fail due to water infiltration or because of a design flaw, limiting heat sinking, leaving you stranded. Using the accessory socket or an SAE battery connector and this cable as a temporary fix, you can bypass the failed controller and get back on the road."

    http://burnsmoto.com/bmw-fuel-pump-bypass-cable.php

    Installation instructions:
    http://burnsmoto.com/bmw-fuel-pump-bypass-instructions.php

    MY set of instructions from the Burns video which I typed out and take with me: Feel free to COPY!

    Fuel Pump Controller BYPASS Installation Instructions

    1. Remove the left side gas tank cover.

    2. Remove the black fuel pump cover.

    3. With a small flat screw driver...pry open the retaining clip and remove the power to the fuel pump controller (
    4. With a torx socket (size T-20) remove the screws that are holding the fuel pump controller to the top of the fuel pump.

    5. On the rear screw...I found it easier to use a torx T-20 screw driver.

    6. With a small screw driver...pry up the fuel pump controller. Look inside and you'll see the BLUE connector.

    7. Use your screwdriver to squeeze the tabs on the blue connector to make it easier to remove.

    8. Now...take your fuel bypass pump cable and align that connector to the top of the fuel pump connector...and connect it.

    9. Insert the Powerlet connector into your accessory socket.

    10. Now...start the bike.
    11. Tuck the cable under the side covers...so they're out of the way.
    12. You're back on the road.
    #7
  8. JimVonBaden

    JimVonBaden "Cool" Aid!

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    What LOPL said.

    It was a big issue in the past, but it is mostly OK now. Since you have a new controller you probably won't have further issues.

    Jim :brow
    #8
  9. FlatDarkGS

    FlatDarkGS Master BS'er

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    It hasn't been an issue because the mega drought has eliminated the "issue" of rain across most of the U.S. Hah! :rofl
    #9
  10. Chat Lunatique

    Chat Lunatique aka El Gato Loco

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    Yup, roger that procedure, I'm on it but pretty fuckin' difficult in a goddamn monsoon with no shelter. I understand the bypass to enable the fuel pump to run 100% dumping the excess back to the tank. But was this not a emergency recovery for earlier model years? Me thought this problem was supposed to be cured before the 2010 models? Or is BMW using up old stock on new bikes?

    PS...I spent 5 hours at the dealer on my 1000km service with the exact same problem after the dealer "powerwashed " my bike for me
    #10
  11. JStancampiano

    JStancampiano PhotoJoe

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    Mine was fine (07 GSAdv) until dealer replaced it under the recall...2 years and 3mo later it failed. O ring was pinched and leaked enough to corrode the connector to the fuel pump. Dealer of course said "someone else could have tampered with it...not our fault". Check that it is not pinched like in photo below!!

    [​IMG]

    Corrosion in connector.
    [​IMG]
    #11
  12. WindSailor

    WindSailor Been here awhile

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    A friend of mine has a '10 GSA and his controller failed too. But his bike acted like it was running out of fuel and finally just died - he couldn't ride it back and had to trailer it home. He had a 911 and it also came up with the fuel pump error.

    He took it to the dealership and they replaced the controller stating that his bike didn't have the new updated model. His old controller had corrosion and was pitted on the board. Supposedly the new controllers have sealed boards... that's all the upgrade was about.

    Maybe I'll just open mine up and look to see if mine is sealed... '11 GSA.
    #12
  13. bemiiten

    bemiiten League of Adventures

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    Anyone know which is Positive, Blue or Yellow?
    #13
  14. WindSailor

    WindSailor Been here awhile

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    One very important note that is stated on the web site:

    I would add to LaurelPerryOnLand's list that your Powerlet Socket (or what ever socket you are using) has to be connected to the battery therefore by-passing the canbus system.

    Nice little piece of insurance. Bought one.:clap Now I'll probably never have to use it, but that's fine with me.
    #14
  15. prince_ruben

    prince_ruben Long timer

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    I rode to work in the rain and my bike ran fine. After 8 hours of sitting in the rain, I rode it home only to have my 2008 1200 GS stall partial home. Bike just shut off. I restarted the bike and it won't idle unless I hold the throttle open. Tomorrow morning I'll inspect the fuel pump for corrosion.
    #15
  16. prince_ruben

    prince_ruben Long timer

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    Update. Let the bike sit in the garage last night. Turned the key and it started right up. I'm gonna pull the fuel pump controller and give it a look over.

    My bike is a 2008 and it seems like modern models have the same issue. Was the design flaw never re-engineered? I ask because I have a warranty and will take it to a dealership and have it replaced.

    Thanks.
    #16
  17. prince_ruben

    prince_ruben Long timer

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    So I inspected the fuel pump controller. Around the housing I found small pebbles and rocks and the surface was completely dry. This was approximately 15 hours after I had issues with stalling. Inspecting the gasket on the controller reveals some dried dirt on both sides of the fuel pump controller. Inside the chamber where the connection is made to the fuel pump there was a small droplet of water in the corner. I unplugged the fuel pump controller's blue harness and it was dry and corrosion free. At this point I'm going to clean the gasket and look for methods to test the controller's function.

    [​IMG]

    Note very small droplet of water in corner.
    [​IMG]

    Note areas of minor corrosion on surface of controller.
    [​IMG]

    Note lack of evident of water on plug harness
    [​IMG]
    #17
  18. prince_ruben

    prince_ruben Long timer

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    Update:

    Just stopped by the dealership to look at the fuel pump controller and gasket. Gasket is the same, fuel pump controller is different from what I have. Mine is silver, dealership had a black plastic unit.

    Talked to service and it's replaceable under warranty (my bike has an aftermarket warranty). Hopefully the stalling was recorded in my computer. We'll see.:clap
    #18
  19. Chat Lunatique

    Chat Lunatique aka El Gato Loco

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    27B7 is the expected fault, but like I said earlier, mine faulted at 1000KM inspection due to powerwashing without the fault code.

    In your last 2 photos I see what appears to be significant corrosion on the "downstream" side of the O ring along with debris on the female seat in photo 2. Should be factory fresh on this side of the O ring if it was intact. I think the seal was bybassed by water for quite some time.
    #19
  20. Rogue Agent

    Rogue Agent Adventurer

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    I have an '07 GSA and can't tell you how many torrential rainstorms I either rode through or the bike simply endured while parked in Panama for two years. Never a problem.
    #20