Fuel Pump & Filter

Discussion in 'Parallel Universe' started by guzzimike, Oct 15, 2012.

  1. guzzimike

    guzzimike Long timer

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    Maybe I should have put this with the other, "My fuel pump has crapped out" threads, but figured they were getting a bit top heavy.
    On a recent epic trip across Australia (which ended in Shitsville BTW) the bike started having the usual failing fuel pump symptoms, as the day wore on and warmed up the bike would start cutting out, this got worse as the days wore on until the bike became unrideable.
    Then I binned it on a crappy bit of track in Far North Queensland, got a ride with the Flying Doctor and the bike was trucked home. This saved me from worrying about it until now.
    (It's an ill wind eh?)
    I ordered a new pump from these guys
    http://www.highflowfuel.com/i-8927843-new-intank-efi-fuel-pump-bmw-f800gs-2006-2010.html
    It duly arrived and I set to work removing the old one & fitting the new.
    A touch of heat from the heat gun is required to remove the convoluted hose from the old pump.
    It was then that I had the bright idea to backflush the filter with petrol.
    You would not believe the amount of crap that came out of that filter!
    It took about 2 litres of petrol poured through it before it ran clean.
    Now this is a bike that has done 50,000km on relatively good quality, non ethanol, clean, dry Aussie fuel.
    The filter is not available as a separate part (it's a Mahle KL315) but only as part of the pump assembly which goes for between $500 and $800, depending where you buy it.
    I am thinking that the fuel pump overheating / dying may be a result of trying to push fuel through this undersized, blocked filter.
    Who ever heard of a fuel filter which is expected to last the life of the bike, no matter what sludge is served up to it?
    Only bloody BMW.
    Right now I am putting the flushed out filter back in, but next on my list of things to spend money on with this crack whore of a bike is an aftermarket, inline, outside the tank filter from a Holden (Chevvy to you Yanks) or somesuch easy to find, cheap source.
    I will remove the in-tank filter. This is easy as the existing filter mounts on a spigot which will take the hose from the pump.

    [​IMG]
    #1
  2. ebrabaek

    ebrabaek Long timer

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    This is going to be a great writ up...... Thanks Mike....:freaky:clap
    #2
  3. JRWooden

    JRWooden Long timer

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    Thanks Mike!
    It is good to know that the $70USD or less pump can fix a problem that would cost far more if left to BMW....

    So no issues I guess with either mechanical fit or electrical wiring harness?

    In one of the other threads ... there was mention that <!--[if gte mso 9]><xml> <o:OfficeDocumentSettings> <o:RelyOnVML/> <o:AllowPNG/> </o:OfficeDocumentSettings> </xml><![endif]-->[FONT=&quot]Mahle will not seel the KL315[/FONT]<!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:TrackMoves/> <w:TrackFormatting/> <w:punctuationKerning/> <w:ValidateAgainstSchemas/> <w:SaveIfXMLInvalid>false</w:SaveIfXMLInvalid> <w:IgnoreMixedContent>false</w:IgnoreMixedContent> <w:AlwaysShowPlaceholderText>false</w:AlwaysShowPlaceholderText> <w:DoNotPromoteQF/> <w:LidThemeOther>EN-US</w:LidThemeOther> <w:LidThemeAsian>X-NONE</w:LidThemeAsian> <w:LidThemeComplexScript>X-NONE</w:LidThemeComplexScript> <w:Compatibility> <w:BreakWrappedTables/> <w:SnapToGridInCell/> <w:WrapTextWithPunct/> <w:UseAsianBreakRules/> <w:DontGrowAutofit/> <w:SplitPgBreakAndParaMark/> <w:DontVertAlignCellWithSp/> <w:DontBreakConstrainedForcedTables/> <w:DontVertAlignInTxbx/> 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mso-style-priority:99; mso-style-qformat:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> filter in the aftermarket that it is a captive part to BMW ...what a load of crap.... perhaps we can find a replacement unit of similar dimensions.

    Your idea of external mounting is good I think - In one of the other threads which I can not find ATM a guy did that...
    He managed to find a rather long slender filter and strapped to the top of one of the frame rails .... seemed to work fine!
    You would also get the advantage of another ~1/4 liter of fuel capacity by moving it!
    #3
  4. Camel ADV

    Camel ADV Long timer

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    What did the pre-pump filter sock look like? I haven't worried about the canister filter because the sock has always been debris free. Now I'm thinking I should have a look anyway.
    #4
  5. guzzimike

    guzzimike Long timer

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    Clean as a whistle


    #5
  6. Camel ADV

    Camel ADV Long timer

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    I just pulled my canister filter and like your's, a ton of junk came out when I back flushed it. Too bad its not replaceable :deal
    #6
  7. Indy Unlimited

    Indy Unlimited Long timer

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    Can we buy a Mahle KL315 or equivelant filter anywhere? Any one have a solution that will fit in the stock location?
    #7
  8. guzzimike

    guzzimike Long timer

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    I am fast coming to the conclusion that this filter is the root of the problem.
    If you think back a lot of the "Bike is cutting out" posts came from inmates stuck somewhere in the 3rd world.
    Think "crappy gas, blocked filter"
    I just can't believe that BMW think this is a life of the bike service item. FWIW the local dealer's service manager agrees with me.
    Every vehicle I have ever owned scheduled a fuel filter change at about 40,000 km.
    As soon as the bike gets back from having the crash damage repaired I will be removing the in tank filter and replacing it with this one mounted externally.
    [​IMG]

    This is a filter for a Peugeot 206/306 and was chosen for the very good reason that I had it in the shed left over from a car I no longer own.
    #8
  9. guzzimike

    guzzimike Long timer

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    Maybe someone can Indy, but I have just wasted about 8hrs of my life trying to do so without success.
    The Mahle is only sold to BMW as far as I can see from posts on other forums.
    #9
  10. ebrabaek

    ebrabaek Long timer

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    Mike, I absolutely agree with your assessment. It is on a list of things...." what on earth were they thinking" Perhaps if we focus on hunting down a solution, we can just shine where BMW did not, and make this work. Don't feel bad though..... We just bought a 11 Mil Jet, and you would not believe the stuff they are trying to pull on the design. One has F8GS written all over it. Simply amazing, when people does not think. Good work.:clap
    #10
  11. Indy Unlimited

    Indy Unlimited Long timer

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    Thanks for all your efforts and research GuzziMike. Look forward to see where you mount and how you route the external filter.:1drink
    #11
  12. cathulu

    cathulu Been here awhile

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    My bike has stalling issues in heat, with low miles and good gas. I got video recently of it happening and will link it and for my dealer to see. The filter is not behind a lot of the stalling issues but may be behind some.

    Sent from my GT-I9100M using Tapatalk 2
    #12
  13. Steveman

    Steveman Been here awhile

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    I wrote an e-mail to Mahle in Germany, will let you know what they tell me...

    Steve
    #13
  14. guzzimike

    guzzimike Long timer

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    Good work Steve:clap
    #14
  15. LukasM

    LukasM Long timer

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    They will probably tell you that they cannot sell parts made for an OEM manufacturer, and not even give you any specs.

    I had the same problem when I called Rotax to find out the transmission ratios when the bike first came out, like those things would stay a secret.... :baldy
    #15
  16. njoytheride

    njoytheride NJOYN' THE JOURNEY

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    Sure appreciate all the great information that comes from these threads. Thanks
    For reference purposes I was in Colorado going over some 12,000 foot passes and my bike starts this dying routine at highway speeds coming into the town. We had to decide if we wanted to chance going over the last pass with my bike cutting out and dying. Cleaned the vent tube on the Carbon filter and went for it. Would have been a hugh recovery fee if it had crapped out deep in the mountains.
    #16
  17. guzzimike

    guzzimike Long timer

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    Location:
    Them Thar Hills WA Australia
    Well, the bike has come home from rehab, sporting it's new subframe & other bits, so it's time to set to work.
    First off I remove the pump from the tank, the book specifies a special tool to undo the locking ring, but, hey, I'm just an Aussie truck driver, so I used a hammer and punch.

    [​IMG]

    Once the pump is out I remove the filter and set the outlet from the pump onto the spigot that the filter used to mount to.

    [​IMG]

    The hose that previously fitted to the barb on the top of the tank is pulled down and forward and becomes the outlet from the new filter to the injection rail.

    [​IMG]

    Note the Compufire regulator, this is being fitted at the same time, hopefully saving my stator.
    A new hose is then run from the tank to the inlet of the filter, then the filter is zip tied to one of the hoses running from the Touratech Tank.

    [​IMG]

    This may seem a bit dodgy brothers, but my thinking is that a flexible mounting is superior to a rigid one.
    Besides, it was easier.
    Fired it up, all good. Will test it this weekend on the annual OCBR.
    I can now replace the fuel filter at regular service intervals at minimal cost.
    A bit of a no-brainer really.
    #17
  18. greenthumb

    greenthumb b00b

    Joined:
    Dec 13, 2008
    Oddometer:
    265
    Location:
    Okanagan, British Columbia
    I like this. Looks good. :thumb

    I wonder what the micron rating is on our oem vs. aftermarket fuel filters and how it will affect the injectors.
    A clear and/or reusable one would be nice.
    #18
  19. greenthumb

    greenthumb b00b

    Joined:
    Dec 13, 2008
    Oddometer:
    265
    Location:
    Okanagan, British Columbia
    Something like one of these.

    fuel filters

    10 micron rating and washable. I think most paper filters are good for around 30 microns.
    #19
  20. Steveman

    Steveman Been here awhile

    Joined:
    Sep 14, 2011
    Oddometer:
    471
    Location:
    Austria
    Hi Lukas

    They replied last Friday and told me to go to a local dealer ATP in Vienna. I was out for a business trip in Poland and just came back on Friday so had no time to check, However, I wrote an e-mail to ATP lets see waht they tell me. Will not have an answer before WEdnesday cause I have to go to Romania tonight.

    Cheers Steve
    #20