R1200GS Fuel Pump Failure

Discussion in 'GS Boxers' started by Dutchman, Oct 25, 2004.

  1. Poolside

    Poolside Syndicated

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    <BR>If you are in a fix, the controller can be bypassed. The fuel pump can be powered directly from the 3-pin connector that plugs into the fuel pump controller.

    The fuel pump controller isn't part of the CANbus.

    Jumper from Pin 1 and Pin 2 on this connector shown below . . .

    [​IMG]

    [​IMG]



    . . . to Pin 1 and Pin 2 on this connector shown below. The numbers 1 and 2 are molded into the connector housing.

    [​IMG]



    The 2 pins of this receptacle below are connected directly to the fuel pump.

    [​IMG]



    The two pins are +12V and Ground, just like other fuel pumps.

    [​IMG]


    Got it? Connect two jumpers, Pin 1 to Pin 1, and Pin 2 to Pin 2, to bypass the faulty electronic controller. This connects power and ground to the fuel pump directly. Just like other fuel pumps that don't have a controller.

    The wire colors in these pictures are different from some versions of the factory wiring diagram. But the pin numbers are correct. The numbers 1 and 2 are molded into the connector housing.



    - - - What does the controller do?

    The controller operates the fuel pump at 80% to extend the life of the fuel filter. The motor ECU switches the fuel pump controller between 100% and 80%.

    The pump can operate at 100% all the time, just like it would without a controller, so a jumper will not be an issue.

    The fuel pump on the 1200 is the same as on the 1100/1150. The only thing new on the 1200 is the 80% controller.

    The fuel pump controller isn't part of the CANbus.



    Another way to bypass the controller is to cut the 2-pin connector from the controller. Use the connector leads to connect Pin 1 to a fuse and the battery positive. And Pin 2 to the battery negative post or chassis ground.

    The pump will be running all the time when the engine is running. But it already is running all the time, just like every other fuel pump.

    If you chose this method, a switch of some kind will be needed to turn the fuel pump on before starting the motor, and off after stopping the motor. The fuse may be plugged/unplugged to serve as a switch.

    Either solution can get you home if you are stuck out on the road or trail, or at a dealer if the controller isn't in stock.

    - Jim<BR><BR>
    #21
  2. xover

    xover Adventurer

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    Hello folks, just received new module (Right one on the pic) 16147694378.

    As you can see the New part has improoved HEAT SINK SURFACE.

    I think it clearly shows that the fault on the previous versions is related NOT to WATER, but to BIG HEAT. SO
    the solution to SEAL the cover will be quite dangerous...:eek1 :eek1

    My question is WHY BMW DID NOT OPENED UFFICIAL RECALL FOR THAT ???

    :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1 :puke1

    It happened already, I changed 4 times all fuel pump KIT, 2 times due to a recall. WHY NOT NOW if it is CLEAR the previous version also gives problems as the oldest one..

    Solution ?!?

    Go to claim on your dealers to replace that part
    it is just 62 EURO and it STOPS the bike.
    #22
  3. Paul-K

    Paul-K n00b

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    Oddometer:
    4
    Hi Jim
    Where can both plugs be obtained from, if one was to make a small harness or adapter cable it would fit easily into a 'on the road' toolkit as a quick and easy get me home fix.

    Well done for the info.

    Rgds

    Paul K (1200GSA)
    #23
  4. Tim Cullis

    Tim Cullis Partially heighted

    Joined:
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    Location:
    London, Granada Altiplano and Morocco
    Bypass wiring

    I'm in Morocco for the next few weeks and my bike isn't going to be near a dealer for some time, so I've done a controller bypass to the existing wiring loom. OK, it's not neat but this is something the dealer is going to have to sort out under warranty when I'm back in the UK.

    The connector running into the TOP of controller has three wires. Bare the right-hand and middle ones (and try not to slash the other in half as I did). Make an 'eye' in each of the cables to accept the splice.

    [​IMG]

    Cut the two cables with terminator block off the BOTTOM of the duff controller and splice
    - the BLUE bottom cable into the BROWN top one
    - the YELLOW bottom cable into the BLUE/GREEN top one.

    [​IMG]

    Cover liberally with insulating tape, plug the terminator block into its position and start engine!

    Tim
    #24
  5. Poolside

    Poolside Syndicated

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    <BR>
    Well done, Tim.

    <BR>
    #25
  6. Racegun

    Racegun Single Track Mind!

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    Great Ideas Guys and thank you! I am going to wire in a switch and small relay. The sw will pull in the relay supplying the NEW BY-Pass voltage to the pump. If it acts like it is running out of gas, a simple throw of the sw should keep me going.

    .............OR........ has this problem been addressed and solved by BMW Motorrad?
    #26
  7. Desert Skies

    Desert Skies One brick shy...

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    And to think, this little meltdown is taking place on the top of your fuel tank.:huh
    #27
  8. AntonLargiader

    AntonLargiader Long timer

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    Thanks for the write-up; saved me some time making this:

    [​IMG]

    This reaches to the accessory plug on the RT I'm repairing. Bike runs like a champ. :thumb

    I'll look at some scrap harnesses and see if I can make one with the right connector on it so it will just replace the module.
    #28
  9. Y E T I

    Y E T I Unpossible

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    If you make them, they will buy them.

    At least I will. :D
    #29
  10. Racegun

    Racegun Single Track Mind!

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    i would pay you for one...heck. i could just buy the connectors.
    #30
  11. Dr Chill

    Dr Chill n00b

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    well that's explained something I found on the 2004 1200GS I just bought from a BMW main dealer. I saw an apparently bodged wiring connector on the fuel pump while I was looking under the plastic cover, but it is clearly the bypass "fix" mentioned and illustrated in this thread! Soooo, do I continue to run the bike as it is or take it back to have the controller fitted under warrenty?

    The bike runs great, by the way.
    #31
  12. andyw

    andyw Been here awhile

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    I'd get the dealer to install a new controller under warranty and keep the bypass wiring icon
    #32
  13. AntonLargiader

    AntonLargiader Long timer

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    I haven't found that connector housing anywhere else on a BMW harness. It's similar to a few others but keyed slightly differently.

    I used some accessory socket wiring (has the right female terminals) from a trashed harness and put that into the blue plug with a BMW plug on the other end. Every dead controller has one of these blue housings, so don't throw them away! Cut the blue end off and save it (or mail it to me!).
    #33
  14. xover

    xover Adventurer

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    #34
  15. Racegun

    Racegun Single Track Mind!

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    #35
  16. RideOnMyFriend

    RideOnMyFriend Adventurer

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    I just had my controller replaced last week on my 07 1200GS and its pn is 16147720776. The turquoise seal ring is still the same recall number 16147694717
    #36
  17. kcodegt

    kcodegt kcodegt

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    Got a 07 R12GSA and just had this problem last month on a dewy Chicago morning, Then last Saturday after my midnight shift and there was torential rains coming down starting the night before. There I am under an overpass soaked with a dead bike, had I known this issue last month I would have just replaced the damn controller my self and made a quick bypass harness for the "just in case" times. Yeah is sucked butt being under that overpass, so I let the rain slow down a bit and then pushed it up the on ramp to the island gs station. Love this bike and I ride in all crazy weather and I am a trained machanic and really do not trust my local dealer, so this thread is a lifesaver. Oh I did have to get towed and I ended driving instead of riding to Indy for the MotoGp's.....

    Thanks
    #37
  18. azgsa

    azgsa Dude

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    #38
  19. azgsa

    azgsa Dude

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    I'm going to ask the dealer to keep my old controller when they open in the morning tomorrow. It's been in there for a week waiting on a new backordered controller. I am NOT going to take this bike on a ride without a bypass harness.
    #39
  20. RichK

    RichK Long timer

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    I asked the dealer to let me keep what I needed to make a bypass harness and got a stern "NO, ALL PARTS ARE RETURNED TO GERMANY". I then mentioned folks are making a bypass harness to not get stranded, and got a "IF YOU READ IT ON THE INTERNET IT'S A LIE". I'm really trying to not be judgemental, and maybe someone was just having a bad day - it can happen. Hopefully it's going to be all right. I was a bit irritated I had to leave the bike vs. getting an initial assessment.

    Rich
    #40