R1200GS Fuel Pump Failure

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

  1. anze

    anze Adventurer

    Joined:
    Jan 15, 2007
    Oddometer:
    13
    Location:
    Ljubljana
    Tried to start the bike yesterday and when i turned on the ignition there was no sound from the fuel pump. So I took out the 911gs and tested the fuel pump and it worked. no Errors no nothing. Went to my friend and borowed his controler. Installed it today and I have the same problem. No sound from the fuel pump upon ignition.

    Now the question here is. With testing the fuel pump with 911gs does this mean that controler also works?

    If it is not the controler thats dead. What is it?

    The Battery is full, kill switch is off. The bike is in neutral.

    br,

    Anze:cry
  2. anze

    anze Adventurer

    Joined:
    Jan 15, 2007
    Oddometer:
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    Location:
    Ljubljana
    Got the bike back today from service. Had it there for one day.

    The mechanic took out the fuel pump and reversed the poles on it, so it started working in oposite way. He tested it than in normal mode and it worked. He said it must have been stained or something.

    It`s weird because it worked with gs911. Well I don`t care cause the ride back home was sweeeet:rofl

    Oh and he gave me a spare controller (used) just for the sake of it. For freeeeee.
  3. TurboCharger

    TurboCharger Been here awhile

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    +1

    Had the exact same problem you described.:waysad Immediately I thought I was the FPC, as I have already had one of these fail, but alas after doing the FPC bypass, the pump still doesn't work, no sound, nothing coming from it when hitting ignition. AND my GS911 doesn't output any error codes regarding the fuel pump. My instinct tells me that the Fuel Pump is failing but my GS911 doesn't confirm it so I'm not entirely sure.

    I will have to pull the entire fuel pump out and test it but before I do this I wanted to know if anyone else has any tricks to test the fuel pump. ie. in a previous post, it was mentioned that reversing the +ve and -ve terminals might work to check if the pump is toast or just blocked. Can I connect a 12V battery directly to the Fuel Pump without any concerns that it will cause a problem?? Are there any issues with reversing polarity??

    Thanks for any advice. :ear
  4. cord4530

    cord4530 danimal

    Joined:
    Jun 23, 2008
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    Location:
    Moscow, ID
    Sorry for a late reply. Assuming the fuel pump wiring is disconnected from the rest of the bike (the blue plug below the FPC is removed) then reversing polarity on the pump shouldn't cause any problems. Being a little DC motor, it will just spin backwards.

    Did you already fix the problem? If so, what did you end up doing?
    -Dan
  5. TurboCharger

    TurboCharger Been here awhile

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    So yes I have fixed the problem, the update is that the FPC didn't actually fail, but I jumped to a conclusion too hastily and ended up soldering a bypass across the FPC anyway. The real problem was the Battery, it was dead, wouldn't even turn the starter (which just went click coincidentally when I hit the start button).

    New battery and new FPC (thanks BMW) and the bike is now back on the road and we're rolling again.
  6. xover

    xover Adventurer

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    May 18, 2006
    Oddometer:
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    Location:
    Sofia, Bulgaria
    Yes, but the battery dead symptoms are completely different than the fuel pump control unit. When the small controller is burned out, happens that your starter (electric motor) is running but the engine does not start. It is also possible to have situation where the engine start for 2-3 seconds than stops (happened to me - considering I have burned several of that electronics).

    So problem determination is not hard here.

    in any case, keep in mind that I have completely removed the electronic module - do not remember if 2 or 3 years ago.
    And have no problems with my bike, about 30 000 km done since that.

    I saw that pert number of the VDO fuel pump is the same as the previous model GS where such electronic was not included in the technical design of the bike. And VDO fuel pump failore was not common issue.
    usually after 120 000 km the pump dies.

    that electronic module has been designed to reduce the fuel pump work load. Good idea, but not really needed considering the reliability of the VDO pump.

    My suggestion is to have a permanent bypass of that module. If your bike has more than 100 000 and you plan a trip, take additional VDO pump. Pump cost is not much higher than the weak module..

    cheers

    Martin
  7. JimVonBaden

    JimVonBaden "Cool" Aid!

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    The module is less than $150. The pump more than $400. Do you have an alternate source for a cheaper pump?

    Jim :brow
  8. xover

    xover Adventurer

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    Hello Jim,
    below is what I found today.
    Actually, last time (3 yrs ago) when I compared prices
    I had 122 euro the electronic
    and 220 euro the fuel pump.

    What I see now, the electronic cost is lower.

    In any case, comparing the duration against cost of the parts it is much cheaper and reliable to stop replacing the electronic module.
    For me that part lasts in medium 17 000 km. The pump should last at least 6 times longer.
    so it comes cheaper.

    02 16147680379 FUEL PUMP 0.75 1 $306.54

    06 16147720776 FUEL PUMP, ELECTRONIC 0.14 1 $131.59


    source:
    http://www.maxbmwmotorcycles.com/fiche/DiagramsMain.aspx?vid=51555&vin=ZL26444&md=200402


    I think if we start searching , might find lower price.

    Other references on electronic module:
    http://www.quellidellelica.com/vbforum/showthread.php?t=72125

    another thing to consider is to keep your fuel tank almost full rather than almost empty. The fuel pump is using the carburant to cool itself too.

    so if carburant level is too low the pump is not cooling well and suffer.
  9. Nitzo

    Nitzo Long timer

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    Daytona
    Mine left me sitting last week-end, 09 adv. A guy brought over the by-pass, but I had no idea about all of this. I told him the connectors were wrong, I was looking at the top of the controller:eek1, I didnt know about taking it off and getting to the plug below. If I had known..............oh well, I just ordered the bypass..............thanks to all for the valuable information.

    [​IMG]
  10. LaurelPerryOnLand

    LaurelPerryOnLand Long timer

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    100 THREADS all GS/GSA owners should read. #19

    COPY and PRINT and take with you in your tools:

    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.
  11. Nitzo

    Nitzo Long timer

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    +1...........:deal
  12. fjteal

    fjteal Adventurer

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    Coldspring, TX
    Is this an issue with 2013 GSA's? My bike just stopped running and has all the symptoms you guys have been talking about. Taking it in to BMW next week.
  13. shereef

    shereef Adventurer

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    Mar 18, 2010
    Oddometer:
    49
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    HALIFAX, NS
    Hey Guys
    I had the stranded by the side of the road thing happen. I thought it was the by pass thing and got one. I can hear the pump going when i connect it to the battery, but the bike simply turns over and does not start? Any thoughts or common issues around these symptoms?
    I will check the spark plugs and fuel injectors soon and before doing anything else, like sending it to the dealer.
  14. JimVonBaden

    JimVonBaden "Cool" Aid!

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    I guess we have to assume you have an R1200GS. If so, what year?
  15. shereef

    shereef Adventurer

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    Figured it out. It was a polarity issue. I had the wires in the SAE plug backwards. The sound of the pump was what threw me off. Bike is back and running. Just need a new Fuel Pump Controller.
  16. shereef

    shereef Adventurer

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    Its a 2006 GSA 12
    :-)
    I was going to actually email you Jim. I have bought your DVD in the past. Awesome stuff.
    JimVonBaden likes this.
  17. JetSpeed

    JetSpeed Naviator

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    Kind of up there with the: "Never mind, I was trying to use the key to my wife's car"
    shereef and JimVonBaden like this.