R1200GS Fuel Pump

[Dutchman]

My recent trip to Germany & Holland was blighted by not one but two breakdowns apparently caused by the same thing, that the first dealer thought he had cured, but obviously hadn't.

If you remove the left hand fairing panel you see the fuel pump cover made from black plastic with slots in it.

http://www.bmwridersscotland.com/Forums%20Photos/GSfuelpump05.jpg

After removing this cover, which is just a push fit, you'll see two electrical connectors & one quick fit fuel connector. The orange circle approximates the area which was filled with water when the first dealer removed the cover. The silver coloured component is the CanBus controller for the fuel pump.

http://www.bmwridersscotland.com/Forums%20Photos/GSfuelpump04.jpg

Undoing two Torx screws enables the CanBus controller to be eased away from it's mounting. There is a rubber 'o' ring which seats between this component and the top of the fuel pump assembly.

http://www.bmwridersscotland.com/Forums%20Photos/GSfuelpump03.jpg

When the blue push fit connector is released the CanBus contoller can be removed. The void below was also about half full of water, causing intermittent electrical shorts, which caused fuel pump failure, the symptom of which was just like running out of fuel, even though plenty was in the tank.

http://www.bmwridersscotland.com/Forums%20Photos/GSfuelpump06.jpg

Here is the CanBus controller top & bottom view........the underneath is sealed with black silicone & the second dealer in Germany suggested that water ingress to this component was the definate cause of the breakdown rather that the now completely dried out electrical connections.

http://www.bmwridersscotland.com/Forums%20Photos/GSfuelpump02.jpg
http://www.bmwridersscotland.com/Forums%20Photos/GSfuelpump01.jpg

Replacing the CanBus controller has certainly cured the problem and I've now ridden about 500 problem free miles!!

Clearly there seems to be a design fault in a plastic cover, which is fairly obviously exposed to the weather when the bike is in motion, that then allows water ingress to an area containing three electrical connectors and where there is no drain for any water to immediately disperse.

For a motorcycle that is marketed as an all weather/all terrain vehicle this is quite simply unacceptable. The German dealer said he had replaced no fewer than five of these devices under similar circumstances and that he had, on each occasion, reported his findings back to BMW.

So that I am not further inconvenianced personally I shall devise a way of preventing the water ingress, but I have also written to BMW asking for an explanation.

Their reply will be published here.

Cheers

Dutch

[MarkF]

Those two big old Bing carbs look better and better every day. Can't say enough good things about the reliability of gravity.

MarkF

[dbrick]

Very nicely explained (and illustrated!), Dutch.

I wonder about the slots in the fuel pump cover. I wonder if they're there to provide a bit of ventilation. (I don't know why ventilation would be necessary there, but I desperately want to believe that the designers didn't put them there for show!)

It would be easy enough to seal the cover to prevent water accumulation as you experienced. Perhaps it should be done in a manner which still allows a bit of air circulation.

[Montana]

You've got a fuel pump that's not buried in your fuel tank? Lucky dog!

Stick a zip-lock baggie upside down over that thing, so that it is protected from water but lets it breathe. Works for the Christmas light plug in out in the yard every winter.

[lkchris]

Moderator!

Another thread that belongs under Oilheads.

[Dutchman]

Originally posted by lkchris
Moderator!

Another thread that belongs under Oilheads.

Oooops......sorry guys.....my fault entirely........obviously an airhead at heart!!:wow

Cheers

Dutch