BMW G650X Challenge Thread Index

Discussion in 'Thumpers' started by GB, Apr 24, 2008.

  1. khpossum

    khpossum poster

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    Why blame the dealers? They just sell what BMW NA gives them. This is a situation where your inventiveness / google / amazon come into play if you don't want to pay full price for the whole assembly. I would find a way to fix it myself for that kind of money.
    Reg York likes this.
  2. Reg York

    Reg York Boet

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    Looks like some preventative measures are the oder of the day, will pay attention while doing the head gasket this weekend.....
  3. snooker

    snooker AttitudeIsEverything

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    OK JJ and Zac you guys are scaring the crap out of me since I'll be riding Hwy 285 to Gunnison next week! I've got almost 30k miles and have never touched my fuel pump OR the dreaded 4-pin connector on the top of it but I want to know more...

    I've got a bunch of clarifying questions, let's start at the basics. So the wiring connector you unplug has female terminals with wires colored: Green/brown, white/blue, brown, brown.
    [​IMG]

    And the connector on the fuel pump assembly has male terminals:
    [​IMG]

    PROBLEMS:
    1) One common problem is when you unplug the connector that the brown wired connection (on the end) does not unmate and tends to pull the male pin out that is part of the fuel pump assembly, which also leaves a hole. I'll call this the "Brown #4" connection. Is this correct so far?

    2) Zac you said in your case this brown wire was frayed at the connector and shorted against the frame. I'm thinking it is very far (1/2") from the connector to the metal ring (frame) so this must have been a very long fray (not just 1/8" or short, but longer?). I think I see a short frayed wire in the pic below (ignoring the totally uninsulated long replacement bare wire for now). Can you explain how it could touch the frame being so far away?
    As to the long bare replacement wire, I assume you somehow covered it up for your temporary patch so it wouldn't short to the frame again?
    And the leaking gas was coming out of this "Brown #4" hole that was no longer sealed well? SCARY.
    [​IMG]

    3) JJ you said: "I must also note that ALL of the wires inside the fuel assembly ( read the ones in petrol, soaked ) had exposed wires from rubbing against the zip ties. Sorta scary."
    Uh YEAH SCARY!
    So is the picture below a nice new "good" fuel pump assembly? And the exposed wires on your older bad one would have been the ones we see below that are Black, White, Green, Red? If so, then the zip ties you mention are around behind just out of view in this picture?
    [​IMG]

    If so then you are saying your original fuel pump is the one that had partially exposed (bare) wires sitting in the fuel itself??? Is anyone else concerned about this???
    :eekers :eekers :eekers :eekers :eekers :eekers
    seasider likes this.
  4. snooker

    snooker AttitudeIsEverything

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    A kneejerk idea is to not unplug the suspect connector and cut the 4 wires and insert in series a second connector that would be the only one to unplug. Something like a Delphi Weatherpack 4-pin connector. This would keep the male pin connector on the fuel pump assembly intact so nothing could leak out or fail. That might be a preventative measure for at least the connector pin issue?

    [​IMG]
  5. jjmead1

    jjmead1 now THAT"S a bike!

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    I blame the dealers because both of the ones I called didn't take the time to find the pigtail assembly that they actually sell and stock. They could not be bothered to assist me, just sell me the whole assembly.

    I had a rear tail light that would not work. Told me I needed a whole new wiring assembly. $1500

    I called an out of state dealer and found the part I needed.

    I am only blaming Denver dealers, they are very bad.
  6. OZZY-DUCK

    OZZY-DUCK Been here awhile

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    Hi guys,
    I'm new to this thread.
    I'm looking at possibly swapping my fully farkled F800 for a reasonably farkled XC.
    I have never riden one as there are not many around and this one is about 1200 miles away.
    What is the seat height like?
    I'm only about 5 ft 9.
    I would like a bit of an idea before I go ahead and bite the bullet.
    Cheers




    Sent from my iPhone using Tapatalk
  7. seasider

    seasider Just a rider

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    Oct 27, 2007
    Oddometer:
    845
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    Virginia
    FWIW...... I had an f800 and find the x way way better off road an only marginally inferior with the typical hwy riding. Dualsport in general the x is hands down a great fit unless you are prone to packing much more than needed.
    As far as seat height I am 5-10 and have no issues still or riding. Seat sucks but thats an easy fix coming soon for me.
  8. keepshoveling

    keepshoveling Long timer

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    Fun fact: part # 34 51 2 345 822 front wheel ABS sensor is an exact replacement for our rear wheel sensor. So, just hypothetically, if you're riding and a rock hits your wheel sensor and it bends a tiny bit so that you're getting the speedo goes to 0 issue you can just swap one out from basically any of the 650s for the last fifteen years or the 800. It's cheaper and much easier to find used and in excellent condition this way.
    DGR and Dutchgit like this.
  9. mtncrawler

    mtncrawler Long timer

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    Fort Collins, CO
    Got it - yep I always set the trip meter at fuel ups - was just curious if there was a quick fix. Sadly, the thought of the 90 MPG I MUST be getting has been shattered....


    One from the road...
    [​IMG]
  10. OZZY-DUCK

    OZZY-DUCK Been here awhile

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    Cheers mate,
    That's what I was hoping.



    Sent from my iPhone using Tapatalk
  11. motorrat

    motorrat Been here awhile

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    For everyone
    http://advrider.com/index.php?threads/bmw-g650x-issue-log-xcountry-xchallenge-xmoto.487473/ page 39
    mtncrawler and keepshoveling like this.
  12. jjmead1

    jjmead1 now THAT"S a bike!

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    @snooker
    Yeah my Brown#4 male pulled out badly leaving the mess you described. ( one could read that wrong I think :eek2) As for the exposed petrol soaked wires. Yeah, they were the oem ones. The very same ones you see in the lower portion of the picture. They are oem zip tied to the aluminum support structure in the fuel pump assembly. I did not replace the whole pump assembly nor do I plan to tis time. I plan on ordering the $89 pump I got last time and hoping I find the reason it only lasted one year. I also plan on making sure those wires are still covered and not exposed again.

    Thinking my male to female wiring connector problem could not be solved in a reasonable fashion, I went a little bonkers. I did try to google similar connectors, and went to the dealers. Apparently my google fu was as bad as the dealers desire to actually help. So, I went full redneck. I drilled a small hole in the top of the fuel assembly. I then soldered brown #4 wire to its mate after I pulled it thru the drilled hole. Sealed up the hole and away I went. Super redneck knee jerk reaction,but it worked very well and seemed solid in its logic until I saw the above posts from you and a few others ---- who have much better google fu than I apparently. :fpalm

    Now I will try to un redneck my redneck fix and go do it the more civilized manner.
  13. motorrat

    motorrat Been here awhile

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  14. MJS

    MJS Long timer

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    The bare wires are not an issue in the fuel tank. It takes the proper ratio of fuel / air AND an ignition source to create a problem. The atmosphere inside the tank is to rich, i.e. not enough oxygen.

    The brown wire is a ground wire. It is probably failing due to high a current draw from the fuel pump. I've seen this on cars/trucks (GM especially) when fuel filters don't get changed on schedule. The pump has to work harder and pulls more current. The connector is sized without much excess current capacity and overheats. The more it heats up the higher the resistance. The higher the resistance, the more it heats up. Until the connection burns up and the fuel pump "fails". If you change your fuel pump be sure the screen and filter are clean. Otherwise the new pump will be working extra hard and require additional current.
  15. MJS

    MJS Long timer

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    Regarding the replacement connectors from BMW. Don't expect your parts guy / gal to know much / anything about them. They are in the parts diagrams but it is the service department that usually deals with them (the part number defines it as a service item). In most of the dealerships I've dealt with the service department will have a stock of the various connectors, the parts department may or may not know about or deal with them. Talk to the Service Manager if you can't get anywhere with the parts counter.
  16. tbarstow

    tbarstow Two-wheelin' Fool

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    They a

    The dealeralso has to have a mechanic that is BMW trained to work on wiring harnesses to be allowed to fix this problem.

    Look in to using Rescue Tape to insulate your wiring in the fuel tank.
  17. snooker

    snooker AttitudeIsEverything

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    MJS your explanation the higher current in the ground connection (on Brown #4 pin) makes sense to me. As to bare wires that could touch each other inside the fuel area, even if there is not a spark or fire issue, surely you would be concerned about 2 bare wires touching each other, especially if one is ground. This could at least prevent the pump from working?
  18. snooker

    snooker AttitudeIsEverything

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    That thread is very interesting regarding the fuel pump ground pin on the connector problem, where they basically use a fatter bolt for ground to handle the higher current better.. It also pointed to this NHTSA Bulletin but I don't remember the fuel pump connector recall # 07V376000 being something the dealers were fixing - did I miss that? Has anyone had this done - what did they do?
  19. MJS

    MJS Long timer

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    Well yes, shorted wires would keep the pump from working. Hopefully due to a blown fuse.

    I'm not saying that the bare pump wires are OK. They are an obvious sign of a problem that needs attention. Just that I would not be concerned about the bike exploding under my butt. There have been bare wires in gas tanks since they started putting electric fuel gauges in cars.
    Dutchgit and Len like this.
  20. Meriden

    Meriden Yea whatever

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    Timely link. On a side note, the wife and I come from a German speaking area of Texas and recently started speaking German in the home. This should help wake up some old circuits in the brain.

    Danke

    m
    Dutchgit likes this.