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Thread: Fuel Pump Bypass Cable

  1. #1
    Registered User sunfire's Avatar
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    Fuel Pump Bypass Cable

    I've read about water getting into the fuel pump , disabling it. I did a search but couldn't find an answer: does this also apply to an '09 GS, or just to pre '07? Should I even consider this?

    I usually tour alone, and I wouldn't want to be stranded because of something like this. Thanks,

    Paul
    R1200GS Adv. ()
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  2. #2
    Cam Killer marchyman's Avatar
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    Not the fuel pump, but the fuel pump controller. It can happen to any bike where the O ring seal failed or wasn't seated right. Here's what the recall notice said

    BMW IS RECALLING CERTAIN MODEL YEAR 2006 THROUGH 2008 R1200 GS MOTORCYCLES MANUFACTURED BETWEEN AUGUST 2006 AND JANUARY 2008. THE SEALING OF THE FUEL PUMP CONTROL UNIT HOUSING MIGHT BE INSUFFICIENT AND WATER COULD INTRUDE INTO THE CONTROL UNIT HOUSING CREATING A HUMID ATMOSPHERE. UNDER SUCH CONDITIONS, THE FUEL PUMP COULD CORRODE AND THEN FAIL.

    Yeah, it said fuel pump, too. Not true. The pump is inside the tank and is not effected. Well, it will stop getting power if the controller fails.

    You could dummy up a bypass cable in the field if this should happen to you. All you need is to cut the controller to fuel-pump connector off the failed controller and jury rig it (with some wire, you do carry wire, don't you) to the connector that goes from the wiring harness to the fuel pump controller. At least that is my plan should the controller ever fail on my '05.

  3. #3
    BMWRich58
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    Quote Originally Posted by marchyman View Post
    Not the fuel pump, but the fuel pump controller. It can happen to any bike where the O ring seal failed or wasn't seated right. Here's what the recall notice said

    BMW IS RECALLING CERTAIN MODEL YEAR 2006 THROUGH 2008 R1200 GS MOTORCYCLES MANUFACTURED BETWEEN AUGUST 2006 AND JANUARY 2008. THE SEALING OF THE FUEL PUMP CONTROL UNIT HOUSING MIGHT BE INSUFFICIENT AND WATER COULD INTRUDE INTO THE CONTROL UNIT HOUSING CREATING A HUMID ATMOSPHERE. UNDER SUCH CONDITIONS, THE FUEL PUMP COULD CORRODE AND THEN FAIL.

    Yeah, it said fuel pump, too. Not true. The pump is inside the tank and is not effected. Well, it will stop getting power if the controller fails.

    You could dummy up a bypass cable in the field if this should happen to you. All you need is to cut the controller to fuel-pump connector off the failed controller and jury rig it (with some wire, you do carry wire, don't you) to the connector that goes from the wiring harness to the fuel pump controller. At least that is my plan should the controller ever fail on my '05.
    All above very good information...

    I went through the FPC breakdown issue last spring down in Texas' *No Mans Land*.

    Actually 2 different problems can occur....
    #1 Water engress to FPC and
    #2 mechanical/burnout failure of FPC.
    The older styled *silver colored* FPC was burning out, and not from water engress. The new replacement part is this newer style *Black painted* FPC.

    Issue fixed by Dealer,450 mile tow covered by BMW.

    When I got back home to Chicago,I disassembled and "resealed" the FPC connections and gasket for better protection and *piece of mind*.
    Then went one step futher and purchased the FPC by pass line (about $26.00)and carry it in the bike.

    Currently closing in on 40K miles on my bike,have been through torrential down pours,multiple hy pressure washings and no problems what so ever with water engress...

  4. #4
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    Rich -

    "purchased the FPC by pass line (about $26.00)"

    What exactly is this, and who sells it?

  5. #5
    Focused kbasa's Avatar
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    Quote Originally Posted by Sailorlite View Post
    Rich -

    "purchased the FPC by pass line (about $26.00)"

    What exactly is this, and who sells it?
    Fellow MOA forum member Stephen Burns (Burnszilla) www.burnsmoto.com, I believe.
    Dave Swider
    Marin County, CA

    Some bikes. Some with motors, some without.

  6. #6
    Registered User sunfire's Avatar
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    Thumbs up

    Again I have to thank everyone in this forum for the quick answers to my questions! You guys are great!

    Much appreciated.

    Paul
    R1200GS Adv. ()
    R1150R Rockster (Sold)
    Buell XB12R (Sold)
    Kawasaki's, ... (youth)

  7. #7
    Benchwrenching PGlaves's Avatar
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    The issue is that the harness has 3 wires connected to the controller - two of which power the pump. The controller varies the speed of the pump. If the controller dies no power gets through it to the pump.

    So to get you home you go around the controller by applying 12v and ground directly to the two terminals on the top of the pump motor.

    Having a pre-failure built set of wires is a good idea whether you get it from somebody or make it yourself. Also - pre-failure - locate the pump and the controller and figure out where and how to connect your two wires. I've had it described to me a couple of times but have never done it since I don't own a bike with a controller. I am under the impression that the controller is directly on top of the pump and that it needs to be removed from the pump top to get to the pump terminals, but don't know that for sure.

    I know it has been discussed with photos on some other forums.

    Anybody have good links?
    Paul Glaves - "Big Bend", Texas U.S.A
    "The greatest challenge to any thinker is stating the problem in a way that will allow a solution." - Bertrand Russell
    http://www.bigbend.net/users/glaves

  8. #8
    TourNut
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    Does the Fuel pump controller module recall also include '08 RT's ? That is what went out on mine in Sept. , at only 3400 miles ! I don't know if they replaced it with a "new-and-improved" reliable unit or not, if there exists one . Another electrical reason why I haven't been able to trust this bike yet to go anywhere far.

  9. #9
    BMWRich58
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    Quote Originally Posted by KBasa View Post
    Fellow MOA forum member Stephen Burns (Burnszilla) www.burnsmoto.com, I believe.

    Eggs'zackley!!!! thanks!!

  10. #10
    Polarbear Polarbear's Avatar
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    Mine done just recent';

    I watched as my dealer did mine in about 5 minutes, replacing the controller under recall. It was very quick and easy on the GSA'07. I did not know of the jump wire, carry along emergency fix. Good idea. I never had a fail on mine, however, just a recall. The GSA controller is located, top left side of tank and the left fairing panel is loosened to access it. The black Roundell panel only. The faired street bikes probably have a worse time getting to it, I'm not sure. Randy

  11. #11
    Registered User
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    The silver controller failed on my 2007 RT @ about 13,000 miles. The dealer replaced it with the new black one. Its a simple repair. The controller is located under the clutch side upper fairing, on the fuel tank.
    2013 Triumph Trophy
    2007 R1200RT Broken driveshaft @ 54,000 miles. Come on BMW!
    2000 R1100rt sold @ 72,000 Great Bike!
    Iron Butt #24605

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