R1200GS Fuel Pump Failure

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

  1. xover

    xover Adventurer

    Joined:
    May 18, 2006
    Oddometer:
    34
    Location:
    Sofia, Bulgaria
    after several failures (4 or 5) on the fuel pump module, I bypassed it. For the moment about 3000km it is running smoothly.
    The fuel pump is the same model used in the R1150xx. So there should be no problem when this unit is running always 100% load.
    The only weak point could be the fuel filter situated in the FLANGE.
    Cheers :freaky
    #81
  2. Burnszilla

    Burnszilla BurnsMoto.com

    Joined:
    Jun 10, 2005
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    1,366
    Location:
    Redwood City, California
    That's good to know.
    #82
  3. Burnszilla

    Burnszilla BurnsMoto.com

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    Location:
    Redwood City, California
    I just got a call from a guy in New Mexico who said his friend's 2008 R1200GS ADV had the fuel controller fail. Looks like the new tank design with 'better drainage' is not working.... Was the tank redesigned on the 08 GSA or just on the GS?
    #83
  4. BV BEEMER

    BV BEEMER Can I see some ID?

    Joined:
    Jul 18, 2006
    Oddometer:
    563
    Location:
    Some RV park Somewhere
    My bike died on the way home yesterday. It sounds like this could be the problem.

    How do I diagnose this without actually tearing into it? Or is the only way to just jump the wires?

    Thanks
    #84
  5. mrmaico

    mrmaico Long timer

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    Feb 26, 2005
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    Location:
    High Plains
    I read somewhere last week that the GSA didn't get redesigned, it was just the GS. I think I have the link with pics on my home pc. I'll try to remember to post a link later today.

    Barry

    EDIT: Found it.....http://www.motorcycleinfo.co.uk/index.cfm?fa=contentGeneric.nvxszdkebklxuaer&pageId=233223

    Lots of other good info at this site as well....
    http://www.motorcycleinfo.co.uk/index.cfm?fa=contentGeneric.home
    #85
  6. kaosrider

    kaosrider Been here awhile

    Joined:
    Aug 17, 2007
    Oddometer:
    998
    Location:
    Jacksonville, Fl
    Hi, Just found this thread, my bike left me standing with what I guess to be this problem. Planning to go to rally in Tenn. My dealer is several hours away.
    I will be buying this by pass...thanks for saving my life...
    #86
  7. andyw

    andyw Been here awhile

    Joined:
    Apr 3, 2007
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    Weston Super Mare - UK
    Thanks for that.....none of it possible without great resources like ADVRider :D

    A more recent article:
    1200gs - variation on fuel pump controller bypass lead
    ....probably the best FPC bypass lead in the world :jjen
    #87
  8. Mr. Magoo

    Mr. Magoo TeeMarrZee

    Joined:
    Oct 10, 2006
    Oddometer:
    5,064
    Thanks for the cable S. Burns. Excellent rapid service and a nicely made product. Hope I never need it, but if I do, I've got the fix. :D
    #88
  9. jdbski

    jdbski old but getting younger

    Joined:
    Aug 3, 2004
    Oddometer:
    464
    Location:
    Santa Monica, CA
    my buddies 05 just crapped out because of this controller, so being a good guy he bought three of the bypass cables, one for himself and one each for his two buddies, now thats what i call a friend!

    Great cable well made and just the right length.
    #89
  10. Tantalum Kid

    Tantalum Kid n00b

    Joined:
    Aug 15, 2009
    Oddometer:
    5
    :eek1 Whooo

    I just got my bike back from the BMW Dealer (Calgary, Canada) after having the fuel pump controller replaced. The bike was down for 18 days. They did the work at BMW's cost, but it did not turn up on the list of "Technical Campaigns" for the bike (R1200GS, production date March 2008).

    I've order the cable from Burns, and hopefully it will arrive soon. Its good to have the bike back, but confidence is not high!

    I also checked into getting a fuel pump controller as a spare. Other discussions mentioned the price of a new controller at 65 Euros and $95 USD. At the one and only Calgary BMW dealer the quoted price was $216.81 CAD (0.90 CAD ~ 1.00 USD). Question - could this part be ordered via www? (PN 16147720776)

    BTW, I saw the old fuel pump elecronic controller they took out and it looked great. Not dirty, no corrosion, the plastic cover (epoxy) was intact with no cracks, the connectors looked good (shiney contacts), and the turquois o-ring looked and felt good without cracks. It was "to be returned to BMW".

    Jim
    #90
  11. Brahma

    Brahma Been here awhile

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    May 19, 2008
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    Location:
    Tampa, FL
    I got my cable from burnsmoto.com and am damn glad to have it.

    Thanks!

    D.
    #91
  12. Dave RII

    Dave RII n00b

    Joined:
    May 9, 2009
    Oddometer:
    8
    Location:
    Western NY
    You should be able to get it here....

    http://www.ecstuning.com/Search_BMW/16147720776/
    #92
  13. Drif10

    Drif10 Accredited Jackass

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    Jun 12, 2003
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    48,033
    Location:
    Gates of Moscow
    They finally issued the recall notice in canada last week.
    #93
  14. SocalRob

    SocalRob Long timer

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    Location:
    Los Angeles @ base of Angeles Crest Hwy
    I had my bike in for tires today (in the US) & they told me there was a "campaign" for the fuel pump controller & they gave me a new one without my asking. Official recall won't happen for a bit they said (months).
    #94
  15. sonic578

    sonic578 Been here awhile

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    Mar 6, 2007
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    765
    Location:
    SE Florida
    Yesterday I had mine in for the "recall". I was in a hurry so didn't get details of what it entailed, but I had heard about it here . That article suggests it is a seal, and not the controller itself?? It would be good to get the facts. I'll try to get more info from the dealer on Monday and post here.
    #95
  16. SocalRob

    SocalRob Long timer

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    I was told they replaced the fuel pump controller. It would make sense that if the old seal was faulty they would not just replace the seal, as the existing controller might already be damaged.
    #96
  17. sonic578

    sonic578 Been here awhile

    Joined:
    Mar 6, 2007
    Oddometer:
    765
    Location:
    SE Florida
    Confirmation from my dealer that it was indeed the controller that was replaced and not just a 'seal':
    The part that was replaced was the electronic mechanism inside of the fuel pump, part #16147720776. It was replaced because the old style let water get in there...
    #97
  18. EJV

    EJV My Dashcam Amuses me

    Joined:
    Jun 26, 2008
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    978
    Location:
    C'Bus
    Mine is in for this right now. They had the part, but, are waiting on the "sealant". Sounds like it gets sealed in Goo (silicone?) to keep any water out.

    Sigh. I miss my bike.
    #98
  19. SullyTX

    SullyTX Adventurer

    Joined:
    Jun 16, 2008
    Oddometer:
    32
    Location:
    East TX
    I come seeking the wisdom of GSpot :D

    My 05 GS recently quit without warning (luckily I was at home at the time). I checked the spark plugs, and they were fine. The bike then started a couple of times, so I left it alone. However, when I went to check it one last time before going to bed, it was back to failing. It will turn over and almost start, but no luck. Today, I thought I might have a bad tank of gas, so I removed the tank (JVB video very helpful), changed the air filter, emptied the tank, and replaced it with fresh gas, but still no luck. I was about to start a new thread asking for input when I saw this one. Is it possible that the fuel pump controller is my problem? I know that the o-ring around the controller on my bike is turquoise colored; does this mean the service has already been done on my bike ?(I'm the second owner, bought it last fall) Would a failed controller cause the situation I described?

    UPDATE: I just disconnected the left side quick disconnect fuel line, then turned the ignition to ON. No fuel came out. Am I correct in thinking that a small amount of fuel should come out of the line when the ignition is switched on? If I am correct, does this provide any evidence that the fuel pump controller is toast? I apologize for my embarrassingly poor mechanical knowledge.
    #99
  20. xover

    xover Adventurer

    Joined:
    May 18, 2006
    Oddometer:
    34
    Location:
    Sofia, Bulgaria
    Hello Gentleman,
    I would like to share my experience with you.
    After 4 consecutive modules burned out, I decide to try the bypass cable.
    My bike is succesfuly running without the fuel pump control unit. It has already around 10 000km :deal without any kind of trouble.

    For my experience the control module lasts in medium 17 000km. That is not enough. Does not matter what release of the module is. The heat is buring that electronics. BMW designed this module in order to make the life of the fuel pump longer and also to save a bit the fuel filter (part of the flange).

    If you look at the ETK you will see that the part number of the fuel pump of the R1200GS is the same as the one of R1150GS.

    R1150GS never had such a module to keep the pump safe. But the fuel pumo of that bike, never had serious issues related. Yes it happened some bike to have problems at 120 000km with the pump.. but it was not that bad. They were very a few, noting to do with the R12 with that module..

    The module is driving the pump to work between 80 and 100% of its power.
    Tha idea was really good but we saw that, it has been realized in very bad way.

    I feel much safer to run my bike without the module considering the very very low reliability it gives. The quality of the pump even running all the times at 100% is 10 times better.

    I think if BMW could cut this trouble (the entire module ) off ...would do this. But I think this is the biggest error of that project and it is quite hard to be admitted. I am still convinced it has been introduced with very very good intention, but the bike was not tested enough before production to realize this could not last. Unfortunately I am still not aware of ANY release that is not burning out of this specific electronic component.

    Best Regards
    Martin