The sorry saga of 1200GS/GSA fuel pump controller failures (410 so far)

[Tim Cullis]

A few things prompted me to start this thread. I've had three direct experiences of fuel pump controller failures in Morocco. One in Azrou to Seatownmaster who had to ship his bike back to Spain in a van, one to me in Chefchaouen where I was rescued by Bob Wilson who rode to my rescue with a spare, and one to a World of BMW 'tourist' in Meknes.

Then I found out about PaulM who was stranded for two weeks in Tajikistan and was about to air freight his bike back to Turkey.

The final straw was reading TBM (Trail Bike Magazine) where the brand new 1200GSA that they borrowed from BMW for a back-to-back test with a KTM 990 failed after a couple of hundred miles. So this is obviously still a current problem that hasn't been sorted.

Enough is enough. It's time for BMW to produce A PROPER FIX for the problem, and if this isn't immediately viable, in the meantime to reduce the cost of the spare part to a couple of quid so that those who are concerned can carry a spare, rather than the £76.94 that is reported to be the current price (after a 64% price increase), see http://www.ukgser.com/forums/showthread.php?t=148553

We need to collate how many breakdowns there have been, so please add your name (or details of a friend) if you have had a fuel pump controller failure on a 1200GS or 1200GSA.

- When did it happen?
- Where were you?
- rider name
- bike details (model and year)
- remedy
- How many days work/holiday did you lose?
- Were there any incidental costs?

Tim

Replies will be left on the thread for a day or so after being incorporated into the figures, and will then be added to the archive here.

[Paul G (BHT)]

Tim is trying to collate specific instances here so please refrain from posting anything other than what he is requesting.

I'm sure that by now BMW are aware of the problem, but if a collective 'complaint' is made then surely they will be foolish not to take on board the fact that this situation is causing major disruptions for their valued customers.

I thank you all

BMW are aware of this thread.

[Tim Cullis]

7 known failures in 2004

When: 2004
Where: Coventry
Name: goyl
Bike: 04 1200GS
Remedy: recovered to dealer, had to wait one day for replacement

When: May 2004
Where: at home
Name: Paul Wakefield
Bike: 04 1200GS, low mileage
Note: another failure later in year

When: Jul 2004
Where: Switzerland on holiday
Name: goyl
Bike: 04 1200GS, 4200 miles
Remedy:

Originally Posted by Paul Wakefield

When: Sep/Oct 2004
Where: during an overtake!
Name: Paul Wakefield
Bike: 04 1200GS (second failure)
Days lost: down time did lead to rescheduling work appointments

When: Oct 2004
Where: Germany and Holland (two failures on same trip)
Name: Dutchman
Bike: 04 1200GS
Remedy: recovered to dealer
Days lost: one day immobile

When: Oct 2004
Where: Germany and Holland (two failures on same trip)
Name: Dutchman
Bike: 04 1200GS
Remedy: recovered to dealer
Days lost: another day immobile

When: Oct 2004
Where: Spain
Name: Lunsarboy
Bike: 1200GS

11 known failures in 2005

When: 2005
Name: GSMonkey
Bike:

When: 2005
Where: Yorkshire
Name: skidave4202
Bike: 04 1200GS
Remedy: trailered to dealer

When: 2005
Name: MM
Bike: 1200GS

Originally Posted by marcus

Can't remember the precise timings and so on, but (of three FPC failures)
When: I had one fail in 2005
Remedy: bike recovered & repaired under warranty

When: Jan 2005
Where: Staffordshire
Name: ed4554
Bike: 04 1200GS
Remedy: bike recovered next day to dealer

When: Feb 2005
Name: FortyZA
Bike: 05 1200GS
Remedy: only 380 miles on clock, recovered to dealer

When: Jun 2005
Where:
Name: wife of Boxed-in
Bike: 04 1200GS

When: Jun 2005
Where: Southern Spain
Name: GAG
Bike: 04 1200GS
Remedy: recovered to dealer
Days lost: took five+ days to fix

When: Jul 2005
Name: Mike Peers
Bike: 05 1200GS
Remedy: recovered to dealer, without bike for several days

Originally Posted by Boggy Bell

When: Mid 2005 (sorry for being vague, memory shot to hell)
Where:Outside work on start up
Rider: Boggy Bell (first of three failures - 2005, 2007 and 2007)
Bike : 04 R1200GS
Remedy : Recovered to dealer (Southport), controller replaced, hire car for the weekend
Days lost : No but frustration gained
Cost : Warranty

When: Sep 2005
Where: Aberystwyth
Name: Abelrider
Bike: 1200GS
Remedy: recovered to Suffolk (8 hour journey)

[Tim Cullis]

26 known failures for 2006

Originally Posted by EVO

When: Apr 2006
Where: on way home
Rider: Evo
Bike: 04 1200GS

When: Spring 2006
Where: close to Brussels
Name: GSBand
Bike: 05 1200GS
Remedy: called BMW assist, they sent Belgian AA, then recovery truck. Dealer took 3 days to repair the bike.
Incidental costs: Bike stranded, public transport.

When: 2006
Where: Edinburgh
Name: Kaycee
Bike:
Remedy:

When: 2006
Name: Cuprinol Man
Bike: 05 1200GS
Remedy: two fuel pump controller failures

Originally Posted by marcus

Can't remember the precise timings and so on, but (of three failures)
When: one fail in 2006
Remedy: bike repaired by BMW assist

Where: Ascot
Name: Davethesax
Bike: 1200GS
Remedy: flat bed lorry from BMW Assist

When: Jan 2006
Where: London
Name: freelance
Bike: 1200GS
Remedy: replaced by dealer
Days lost:
Cost:

When: Jan 2006
Where: Yorkshire Moors
Name: Fatboy
Bike: 04 1200GS
Remedy: replaced by BMW Assist

When: Feb 2006
Where: London
Name: Peter Reilly
Bike:
Remedy: replaced by BMW Assist

When: Mar 2006
Where: Herts
Name: quendi
Bike: 1200GS
Remedy: recovered to dealer for spare

When: Mar 2006
Name: Geoff
Bike: 04 1200GS

When: Apr 2006
Where:
Name: xpi0t0s
Bike: 1200GS
Remedy: three hour wait for recovery, several days without bike

When: Apr 2006
Where: North American trip
Name: Geordietraveller
Bike: 04 1200GS
Remedy:

Originally Posted by piebaps

When: May 2006
Name: Piebaps
Bike: 05 1200GS
Remedy: BMW recovery to Dealer and repaired within 2 days (warranty)

When: May 2006
Where: M6
Name: alecmuffet
Bike: 1200GS
Remedy: ferried home, bike recovered to dealer, replacement fitted

When: May 2006
Where: Surrey
Name: Haggerstoner
Bike:
Remedy: covered to dealer, replacement fitted

When: May 2006
Where: Dales
Name: paulhull
Bike: 04 1200GS
Remedy: recovered to dealer

When: May 2006
Where: Wales
Name: dresdahonda
Bike: 04 1200GS
Remedy: recovered home
Days lost:

Originally Posted by EVO

When: 2006
Where: France (70 mph in outside lane of Autoroute)
Rider: Evo's brother
Bike: 04 1200GS
Remedy: waited a day for BMW Assist who said they had a team of driers running around repairing these all over Euroland.

When: May 2006
Where: Wales
Name: Nomad
Bike: 04 1200GS
Remedy: rcovered home then trailered to dealer (out of warranty)
Days lost:
Costs:

Originally Posted by Gipsy

When: Jun 2006
Name: Gipsy
Bike: 54 1200GS
Remedy: recovered and replaced under warranty.
Note: second failure out of warranty July 2007, recovered and fixed by independent BMW mechanic.

Originally Posted by The Bede

When: Jul 2006 1:00am (very feckin' convenient)
Where: A23 Coulsden
Rider: The Bede (John Tremayne) another failure in Jul 2008
Bike 55 plate R1200GS
Remedy: Recovery to home, next day recovery to NOG for same day fix
Days lost: None ... but who the feck wants to be hanging aroung in Coulsden in the middle of the night waiting for a recovery truck, only to have to do the same the next day
Incidental costs: Yes ... I spent £10K on a 'lemon' (bike later replaced with BMW subsidy)

When: Sep 2006
Where: M20
Name: Citybum
Bike:
Remedy: replaced by BMW Assist

When: Oct 2006
Where: Guernsey
Name: Buckhouse
Bike:
Remedy: dealer sent replacement by post

When: Oct 2006
Where: Scotland
Name: smirky
Bike: 1200GS
Remedy: recovered to dealer

When: Dec 2006
Where: M25
Name: Geoff
Bike: 04 1200GS

[Tim Cullis]

50 known failures in 2007

When: 2007
Where:
Name: Lugs
Bike: HP2

Originally Posted by Blaine Dracup

When: 4am on way to Birmingham as wife had gone into labour
Where: M6 Nr Lancaster
Name: Blaine Dracup
Bike: 07 1200GS
Remedy: recovery to dealer
Days lost: 2

When: 2007
Name: Chris IOW
Bike:
Remedy: called AA, then fitted replacement

When: 2007
Name: taselhoff
Bike:
When: 2007
Where: on dealer forecourt!
Name: Gaz

When: 2007
Name: marvellous thingys
Remedy: waited six hours for BMW Assist

Name: friend of Dr John
Bike: 04 1200GS

When: 2007
Where:
Name: petethewelder
Bike: 05 1200GS
Remedy: two instances of controller failure at 24000 and 24500 miles

When: 2007
Where: Scotland
Name: GSoh
Bike:

Originally Posted by Boggy Bell

When: Aug 2007
Where: North Wales.
Rider: Boggy Bell (suffered two other failures in 2005 and 2007)
Bike: 04 R1200GS (same bike as above)
Remedy: Recovered to back street garage, controller bypassed, bike traded in on return from holiday
Days lost: 1 day holiday hanging about
Cost: £50ish, bike out of warranty

When: 2007
Where:
Name: Pressurised
Bike: 54 1200GS
Remedy: picked up by dealer, part replaced

When: 2007
Where: Guernsey
Name: Buckhouse
Bike: 04 1200GS
Remedy: new unit sent by post, replaced by self

Originally Posted by marcus

Can't remember the precise timings and so on, but of three FPC failures)
When: one fail in 2007
Remedy: bike repaired by BMW assist

When: Jan 2007
Where: Spain, on way to Timbuctou
Name: Nick Sanders tour
Bike: 1200GS
Remedy: fixed in Spain

When: Jan 2007
Where: Cambridgeshire
Name: Walti
Bike: 1200GS
Remedy: recovered to dealer

Originally Posted by Happyhenry

When: Feb 2007
Where: M11 Essex
Name: Happyhenry
Bike: 05 1200GS
Remedy: just brought bike from dealer, dealer came in van and new one fitted
Days lost: 1 hour

Originally Posted by DonC

When: Mar 2007
Where: West Coast of Ireland
Rider: Don Carmichael
Bike: 55 plate 1200GS
Remedy: fuel pump controller replaced at Cork BMW
Days holiday lost: 4 days of holiday but BMW Assist paid for hire car and all hotels
Incidental costs? Lots of phone calls and having to drive a car for most of a biking holiday!!

When: Apr 2007
Where: Exeter
Name: DA Cooper
Bike: 1200ST
Remedy: replaced by BMW response

Originally Posted by GAG

When: Apr 2007 (second instance of FPC failure)
Where: Edinburgh, 20 miles from home
Name: GAG
Bike: 04 1200gs
Remedy: Out of warranty so bus to dealers to pick up new controller.
Days lost: 1 day.
Costs: New part, bus fares plus time.

When: Apr 2007
Where: Cleveland
Name: Philh24
Remedy: replaced three days later by BMW response unit

When: May 2007
Where: Leicestershire
Name: Jetjock
Bike: 04 1200GS
Remedy: new controller via dealer
Days work/holiday lost: 1 week

When: May 2007
Where: Sheffield
Name: GSRon
Bike: 1200GS
Remedy: replaced by BMW recovery
Days lost: 1 hour

When: May 2007
Where: en route in Germany
Name: Bert
Bike: 1200GS
Remedy: was carrying a spare so fitted same
Days lost: 20 minutes
Costs: £50 for spare unit

When: May 2007
Where: Oxford
Name: The Kergan
Bike:
Remedy: recovered to dealer

When: Jun 2007
Where: Scotland
Name: Mr Adventure
Bike: 05 1200GS
Remedy: RAC recovered bike to dealer

When: Jul 2007
Where: Austria
Name: Robin
Bike: 05 1200GS
Days lost: happened Sunday, bike ready 10am Monday
Cost: €150 (two months out of warranty)

Originally Posted by patrick

When: 2007
Where: cumbria
Rider: Patrick
Bike: 06 1200GS
Remedy: 3 hrs at side of road, recovered to mill bmw, new controller fitted, returned in 24 hrs

When: Jul 2007
Where: Scotland
Name: Schtum
Bike: 05 1200GS
Remedy: recovered to workshop
Days lost:
Costs: £50 for parts (out of warranty)

When: Jul 2007
Where: on holiday in Yorkshire Dales
Name: phc1058
Bike:
Remedy: recovered by AA
Days lost:
Costs:

When: Jul 2007
Where: Slovenia
Name: eclectic
Bike:
Remedy: nearest dealer was Trieste in Italy
Days lost: several

Originally Posted by GerryC

When: Jul 2007
Where: en route to a meeting in Cork
Rider: Gerry C
Bike: 05 1200 GS
Remedy: Trucked to Cork (Kearys)
Days lost: None but missed meeting.
Incidental costs? 1 week after warranty expired, Carol Nash covered the recovery.
Comment: I now carry a spare and a GS 911 diagnostic unit (along with an EWS ring).

When: Jul 2007
Where: Cork, Ireland
Name: GerryC
Bike: 05 1200GS
Remedy: recovered by Carol Nash
Days lost: no parts in stock

When: Aug 2007
Where:
Name: Fabio
Bike: 05 1200GS
Remedy: replaced by Wollastons

When: Aug 2007
Where: Norway
Name: GP Longford
Bike: 07 1200GS
Remedy: new controller via dealer

When: Aug 2007
Where: M65
Name: Nozza
Bike:
Remedy: replaced by BMW recovery

When: Aug 2007
Where: Wales
Name: Gipsy
Bike: 05 1200GS
Cost: first failure 15 months earlier under warranty, had to purchase replacement for second failure

When: Sep 2007
Where: Bilbao to Madrid
Name: the civil one
Bike:
Remedy: bought new controller
Days lost: two days
Costs: £80 (out of warranty)

Originally Posted by bsogri

When: Sep 2007
Where: Chesterlee Street
Bike: 05 1200GS
Remedy: out of waranty but replaced free

Originally Posted by piebaps

When: Oct 2007
Where: IOM TT Course
Name: Piebaps
Bike: 05 1200GS (second failure, also failed May 2006)
Remedy: RAC Recovery to dealer and repaired within 2 days
Days lost? Lost a Saturday morning's overtime
Costs? Dealer repaired out of warranty after I stamped my feet a little

When: Oct 2007
Where: M1
Name: skinmeister
Bike:
Remedy: substantial recovery delay

Originally Posted by cafemaestro

Name: Cafemaestro
Bike: 07 1200GS
Failed: @ Home, Not sure when - think it was Nov '07
Remedy: BMW Customer assistance came & fitted new part
Lost days: None (had a car) but bike was u/s for 2 days
Hassle: Lots
Worried: Yes - I expect it to go anytime -- Come on BMW - Live up to your advertising hype!

When: Nov 2007
Where: Kendal, Cumbria
Name: Mike R
Bike: Jan 07 1200GS
Remedy: 2 hour wait for recovery (Sat night), bike returned Monday
Solution: sold the bike

Originally Posted by Boggy Bell

When: late 2007
Where : Southport (following a friend demo-ing a GS)
Rider: Boggy Bell (suffered two other failures in 2005 and 2007)
Bike: 07 R1200GSA
Remedy: Recovered to a red faced dealer (Southport), controller replaced, home made cover with vents fitted
Days lost : 1, however, it was worth dealers embarrassment when said friend returned the demo bike with a big no-sale.

When: Nov 2007
Where: Scotland
Name: Sixpack
Bike: 05 1200GS
Remedy:
Days lost:
Cost: £130 parts and labour

Originally Posted by bridgebiker

When: Nov 07
Where: Stranraer
Name: N Thomson
Bike: 04 1200GS
Remedy:Replaced
Days lost:1, because the recovery took until 4 in the morning to get me back and I needed to sleep. Bike off road for 4 days waiting on part
Costs: £90 parts and labour

When: Nov 2007
Where: Wales
Name: willi5852
Bike: 06 1200GS
Remedy:
Quote: BMW do not recognise the problem you describe as an inherent design fault

Originally Posted by Sixpack

When: Nov 2007
Where: home
Bike: 55 1200GS
Remedy: Replaced by dealer.
Cost : £120 for finding fault and fixing.

When: Dec 2007
Where: Kent
Name: Bones
Bike: 06 1200GS
Remedy: recovered to dealer, replacement fitted
Days lost: lost half day's pay

When: Dec 2007
Where: Wales
Name: karnevil
Bike: 06 1200GS
Remedy: replaced by BMW Assist
Days: lost half day wages

Originally Posted by taslehoff

When: Dec 2007
Where: Chorley Lancashire
Rider: Tim James
Bike: GSA1200 2006 / 15,982Mls
Remedy: BMW assist replaced fuel pump relay

[Tim Cullis]

85 known failures so far in 2008

When: Jan 2008
Where: Azrou, Morocco
Name: Seatownmaster
Bike: 07 1200GS
Days lost: holiday cut short by four days
Costs: 200+ mile van transport to port (£180) + (£65 fuel, police 'tips')
plus £663 reclaimed from BMW recovery

When: 2008
Where: Ireland
Name: GSDreamer
Remedy: replaced by self

Originally Posted by Black Cloud

Where: M27
Name: Black Cloud
Bike: 54 1200GS
Remedy: paid for replacement (£75)
Days lost without bike for 4 weeks due to global shortage of replacement
Costs: train tickets to work

When: 2008
Where: New York, USA
Name: Coalburner
Bike: 4000 miles on clock
Remedy: towed to dealer, new controller fitted

When: 2008
Where: Southport
Name: M Hallsworth
Bike: 05 1200RT
Costs: £120 parts and labour

When: Jan 2008
Where: Liverpool
Name: Paulenglish
Bike: 06 1200GS
Remedy: replaced by BMW Assist

When: Jan 2008
Where: London
Name: grendal
Bike: 06 1200GSA
Remedy: replaced by dealer
Days lost: much inconvenience

When: Feb 2008
Where: at work, then at home
Name: Phil Adams
Bike: 1200GS
Remedy: recovered on flat bed

When: Feb 2008
Where: Merseyside
Name: Judda
Bike: 57 1200GSA (less than 1000 miles on clock)
Remedy: BMW Assist didn't have the part (there's a first), so recovered to dealer

When: Feb 2008
Where: Ireland
Name: patzx12
Bike: 06 1200GSA
Remedy: replaced with a spare unit

When: Feb 2008
Where: Sunderland
Name: bsogri

Originally Posted by Owen Snell

When: Mar 2008
Where: Lincoln, pulled up in stationary traffic and it idled for a minute then died.
Name: Owen Snell
Bike: 05 R1200GS
Remedy: Was on a test ride. Dealer came in his van. Bought it anyway.
Days lost: None, a couple of hours max but lucky really.

When: Mar 2008
Where: Istanbul
Name: Expat
Bike:
Cost: €120 for replacement part

Originally Posted by Colebatch

When: Mar 2008
Where: Hillbilly Country, Northern Spain
Name: Colebatch
Bike: 06 1200GSA
Remedy: Paid a non BMW garage to replace it, as the BMW dealer in town was closed for the weekend
Cost: about £100. Bike was under warranty but if I waited for the BMW dealer I would have been delayed at least 2 days and would have to buy a new ferry ticket. Despite being under warranty, BMW would not reimburse me the replacement costs.

Originally Posted by brianmaslen

When: Mar 2008
Where: M6 Keele Services
Name: brianmaslen
Bike: 06 R1200GS
Remedy: called BMW Assist

When: April 2008
Where: London
Name: Trickywoo
Bike: 05 1200GS

Originally Posted by Jonny_L

When: Apr 2008
Where: At home
Name: Jonny L
Bike: 55 1200GS, 8000 miles
Remedy: Bike recovered to Vines via BMW Assist
Days lost: 2 days without bike, but got a free courtesy car so all OK. Missed a night down the pub though
Cost: All free under warranty

When: Apr 2008
Where: London
Name: Patboy
Bike: 1200GS
Remedy: bike recovered to dealer

Originally Posted by Anonymous

When: Apr 2008
Where: at home
Name: Anonymous
Bike: 07 1200GSA
Remedy: BMW Assist had one on board (warranty)
Days lost: 0 but had to take the car that day

When: Apr 2008
Where:
Name: friend of Judge
Bike: 06 1200GSA
Remedy: suffered controller failure twice

Originally Posted by Barfly

When: 3 Apr 2008
Where: on A3 - 3 miles from Guildford.
Name: Barfly
Bike: 06 1200GS belonging to Vines - I was test riding it with a view to buy
Remedy: mechanics from Vines came out (eventually - see my thread of the 4.4.08)
Cost: £s in mobile phone costs.

When: Apr 2008
Where: Surrey
Name: Stephen Shury
Bike: 07 1200GS
Remedy: replaced by dealer

Originally Posted by Mike Oszywa

When : April 2008
Where : Surrey
Name : Mike Oszywa
Bike : 06 1200GS
Milage : 29k
Remedy : BMW emergency fixed on spot

When: 20 Apr 2008
Where: home
Rider: Martyn Buckland
Bike: 07 1200GSA
Remedy: BMW Assist to dealer then new controller fitted. BMW Assist returned it to home

When: Apr 2008
Name: Hangman
Remedy: replaced by BMW Assist

Originally Posted by nick_boxer

When: Apr 2008
Where: Cahors, France
Rider: Nick_Boxer
Bike: 05 1200GS
Remedy: five hour wait, then recovered to a garage, then to BMW dealer
Days holiday lost: a full day getting the bike to the local BMW dealer

When: Apr 2008
Rider: Bill Bradford
Remedy: recovered by AA, bike out of warranty so £80 bill.

When: May 2008
Where: Chefchaouen, Morocco
Name: Tim Cullis
Bike: 2006 1200GSA
Remedy: Bob Wilson rode 250 miles to lend a spare unit , then wiring bypass implemented
Days lost: one complete day
Costs: tank of petrol and expensive hotel

When: May 2008
Where: Meknes, Morocco
Name: loan bike, World of BMW tour
Bike: 1200GS
Remedy: fitted Bob Wilson's spare controller (again)

Originally Posted by DonC

When: May 2008
Where: Oxfordshire
Rider: Don Carmichael (second failure)
Bike: 55 plate 1200GS
Remedy: AA to dealer, controller replaced one from new model 1200, which I'm told is a new design; North Oxford BMW replaced FOC even though out of warranty.
Days work/holiday did you lose? Without bike for a week
Incidental costs? Lots of mobile phone costs.

When: May 2008
Where: Strasbourg, France
Name: Trailbike Magazine on loan from BMW for comparison test against KTM 990
Bike: 2008 1200GSA
Remedy: recovered on truck to dealer
Days lost:

Originally Posted by big_kitch

When: May 2008
Where: outside lane of M4
Name: Nick Kitchin
Bike: 57 1200GS
Remedy: recovered to dealer and repaired under warranty

When: May 2008
Where: at home
Name: Trevor
Bike: 05 1200GS, 13500 miles
Remedy: drove to dealer to collect replacement
Cost: yes, out of warranty

When: May 2008
Where: A90 north of Dundee
Rider: Ian Slorach
Bike: 06 1200RT, 8000 miles
Remedy: flat bed to Aberdeen, without bike for two weeks due to no FPCs available

Originally Posted by brummie

When: May 08
Name: brummie
Bike: 07 1200gs
Remedy: repaired under warranty 2 days

When: May 2008
Where: outside lane, M4
Name: Fabian
Bike: 07 1200GSA
Comment: "I nearly died!"

When: May 2008
Name: friend of Dr John (again)
Bike: 07 1200GS

When: May 2008
Name: customer of Mototech
Bike: 1200ST

Originally Posted by Simong

When: May 2008
Where: Berkshire
Name: Simon Graham
Bike: 05 1200GS
Remedy: new one fitted by BMW dealer £150
Bike was in the dealer for 5 days (I could only get there on the weekend to pick it up), and i had to commute on my GSF1200 instead.

When: May 2008
Where: Scotland
Name: Beemer RT
Bike: 06 1200RT
Remedy:
Days lost: bike off the road for two weeks waiting for new controller

Originally Posted by mac163

When: Apr/May 2008
Where: near home
Rider: mac163 (Lister Cummings)
Bike: 05 1200GS
Remedy: As no spares were available and a 2,000 mile plus trip round Scotland within days away - Technician bypassed relay with direct feed to battery and ran wires to a push connection up below bars.
Incidental costs: not covered under warranty

When: May 2008
Where: Eifel region, Germany
Name: GSBand (second failure)
Bike: 57 1200GS
Remedy: BMW assist sent BMW service mobile, then recovery truck. Next day BMW Cologne stripped a new bike of a pump controller so I could continue my trip.
Days holidays lost: 1 day
Incidental costs? Hotel paid by BMW
Coment: I've bought a spare that I carry with me on trips abroad.

Originally Posted by kenseaton

When: May 2008
Where: near house
Rider: Ken Seaton
Bike: 05 1200GS
Remedy: BMW Assist said no spares in the country, however replaced with one from Riding School bike
Cost: not covered by warranty
Comment: new pump module is part number 16 14 7 719 844

When: May 2008
Name: AlexW
Bike: 06 1200GS
Remedy: recovered to dealer

When: May 2008
Where: Scotland
Name: friend of Tartan Terror
Bike:
Remedy: replaced by BMW breakdown

Originally Posted by strma1200gs

When: May 2008
Where: Colchester, Essex
Rider: stra1200GS
Bike: 04 1200GS 14000 miles
Remedy: recovered using own trailer, hours and hours of self-diagnosis, bike inoperable for several weeks
Remedy: bypassed controller using wiring direct from battery with make/break connection on handlebars and shorting wire on keyring
Cost: £250+ for GS911 + 2M of cable + terminals
Comment: I bought a GS911 diagnostic tool after the failure which eliminated all the other likely causes. I have no intention of replacing the controller since the rewire solution works fine although I'm left wondering whether the pump is now being overstressed.

When: May 2008
Name: GSBand (again)
Bike: 07 1200GS

When: May 2008
Where: Suffolk
Name: oldenoughtoknowbetter
Bike: 07 1200GSA
Remedy: was carrying a spare

Originally Posted by Rat-on-a-GS

When: 3 May 2008
Where: A12
Name: Rat-on-a-GS
Bike: 57 1200GS (mileage 1252)
Remedy: recovered to dealer and replaced
Days lost: 2

Originally Posted by Rat-on-a-GS

and then again one month later

When: Jun 2008
Where: A12 (nearly wiped out by Dutch lorry)
Name: Rat-on-a-GS
Remedy: BMW Assist failed to find fault, recovered to dealer and part replaced
Bike 57 1200GS (mileage now 1874
Days lost: 3

When: Jun 2008
Where: Northern England
Name and bike details: Markgsxr
Remedy: replaced by BMW breakdown

Originally Posted by Temple

When: June 2008
Where: an hour and half from home
Name: Temple
Bike: 07 1200GS, 3000 miles
Remedy: rescued and replaced under warranty

When: Jun 2008
Where: West Midlands
Name: RustyNuts
Bike details: unknown
Remedy: recovered to dealer, two+ days delay in getting parts

When: Jun 2008
Where: Australia
Name: Pukmeister
Bike: 2004 1200GS
Remedy: bike recovered by friend with trailer
Days lost: one

When: Jun 2008
Where: Wales
Name: JFC
Bike:
Remedy: recovered to home, unit on order
Days lost:

When: Jun 2008
Where: Scotland
Name: Temple
Bike: 2007 1200GS
Remedy: recovered to dealer
Days lost: four days without bike

When: Jun 2008
Where: Berkshire
Name: Littlemegdog
Bike:
Remedy: replaced by dealer
Days lost:

When: Jun 2008
Where: Dublin
Name: purtywhipper
Bike: 2006 1200GS
Remedy: transported by van to dealer
Days lost:
Costs: €60 van, €30 labour (out of warranty)

When: Jun 2008
Where: French Pyrenees
Name: Brian
Bike: 1200GS
Remedy: bike recovered
Days lost: 2 days
Costs: paid for parts and labour

When: Jun 2008
Where: Warwickshire
Name: speedy23
Bike: 05 1200RT
Remedy: replaced FOC although out of warranty

Originally Posted by The Bede

And another one, on the bike 'subsidised' by BMW to replace the Lemon.

When: Jul 2008
Where: Tipperary, Ireland
Rider: The Bede (John Tremayne) first failure was in Jul 2006
Bike: 08 1200GSA
Remedy: recovered back to campsite, feck about for half a day waiting for bike to be recovered to Keary's in Cork, feck about for the rest of the day stranded at a campsite, without food or money, waiting for the promised 10:00am rental car. Feck about for another day, not too far from Cork waiting for the fix to be done, news received at 5:30 too late to do anything about it. Feck about the following day rushing to Cork to collect and load the bike then hell-for-leather-it to make the ferry
Days holiday lost: 4 days out of 8 fecked
Incidental costs: £30 in cellphone calls and 4 days of expensive trip down the dunny.

When: Jul 2008
Where: Khorog, Tajikistan
Name: PaulM
Bike: 1200GSA
Remedy: new part send by DHL from UK
Days lost: two weeks

When: Jul 2008
Where: Liverpool
Name: teal'c
Bike: 1200RT
Remedy: drove to dealer to collect replacement

Originally Posted by THE DOCTOR

When: Jul 2008
Where: riding across Germany
Rider: Flash Of The Gap
Remedy: cost €400 to transport to hotel, another rider had a spare

When: Jul 2008
Where: La roche sur yon
Name: frank1200
Bike: 06 1200GS
Remedy: new one fitted
Days lost: 3 days holiday and home 2 days early=5

Originally Posted by Jaythro

When: 12 Jul 2008
Where: tour of Scotland and NE England
Name: Jaythro, Tucker QuayVipers MCC
Bike: 04 1200G
Remedy: wiring bypass carried out, bike out of warranty
Days lost: couple hours lost tryin to get the hold of me BAd signal in the rocks of Dungloe!

Originally Posted by beemerboy9

When: July 2008
Name: Beemerboy9
Bike: 05 1200RT
Remedy: original controller replaced

When: Jul 2008
Where: on way home from work
Name: Steve (RAVANELLI)
Bike: 57 GSA with about 6k
Remedy: 45 min wait for BMW Assist, on road 15 mins later

Originally Posted by gingercoastie

When: Jul 2008
Where: Praa Sands
Name: gingercoasti
Bike: 07 1200GSA, 9378 miles
Remedy: recovered to dealer

Originally Posted by talonfs

When: Jul 2008
Where: M25 outside lane 70mph
Rider name TalonFS (Simon Darch)
Bike: 07 1200GS
Remedy - BMW Assist replaced FPC
How many days work did you lose? Day off work

When: Jul 2008
Where: home
Rider: Toby
Bike: 06 GSA, 42000 miles
Remedy: BMW Assist replaced
Cost: £50 excess on extended warranty

Originally Posted by SpyInTheCamp

When: Jul 2008
Where: Edinburgh City Bypass, while filtering (it was quite 'interesting'!)
Rider: SpyInTheCamp (Kai)
Bike: 05 1200GS, 30,600 miles on clock
Remedy: AA took it to local delaer.
Days work lost: Half a day off work
Incidental costs: taxis plus FPC replacement (out of warranty)

Originally Posted by SkyGod

When: Jul 2008
Where: bottom of Stelvio Pass, Italy
Rider: Gary Pitchford
Bike: 06 1200 GS 34000 miles
Remedy: One of the lads carried a spare as he had heard it was a weakness.
Time lost: 2 hours of holiday lost.
Comment: Will now carry a spare.

Where: Manchester
Rider: Hubarbspong
Bike: 57 1200GS
Remedy: BMW assist to Williams M'chester who would not touch bike for 2 weeks. Got it moved to Alan Jefferies who fixed it same day
Days lost: one day at work (6hrs from initial call to BMW asist to getting to Williams). Spent 2 days ringing Williams, BMW assist and BMW customer services as Williams would not pay for replacement vehicle. Ongoing complaint logged at BMW customer service
as I have had to pay for the hire car for 2 days.

When: 3 Aug 2008
Where: A40 overtaking a lorry
Rider: Gog yn y De
Bike: 06 1200GSA, 21000 miles
Remedy: BMW Assist to dealer then new controller fitted. BMW Assist returned it to home
Days lost: 10 days without bike

When: 6 Aug 2008
Where: Manchester
Rider: Kev G
Bike: 1200GSA
Remedy: pushed home, BMW Assist replaced FPC

When: early Aug 2008
Where: motorway services on M6 nr Preston
Name: Geoff Johnson
Bike: 04 1200GS
Remedy: had spare with me, 15 min DIY job
Cost: £76 for spare

Originally Posted by BarmyFred

When: 6 Aug 2008
Where: luckily 100 meters from home after a 200+ mile journey
Rider: BarmyFred
Bike: 07 1200GS
Remedy: BMW assist took me to Balderstons, Peterborough. New controller fitted while I waited
How many days work/holiday did you lose?: 1/2 a day.
Incidental costs?: Bought some new gloves while I waited and booked a test ride of a K1200R Sport...

When: 11 Aug 2008
Where: Merseyside
Rider: Dave T
Bike: 06 1200GS, 13736 miles.
Remedy: sorted by BMW assist

When: 17 Aug 2008
Where: The engine cut out just after an overtake. Had it happened slightly earlier in another overtake the situation could have been catastrophic.
Rider: rcgd
Remedy: replaced by dealer at my expense

When: 18 Aug 2008
Where: Portree (start of a tour of Highlands and Islands)
Rider: friend of HRH Oonyack
Bike: 56 1200GSA
Remedy: recovered, hired a 1150 to continue tour as part not in stock
Days lost: yes

When: 20 Aug 2008
Rider: Keff
Bike: 05 1200GS
Remedy: BMW assist turned out and confirmed the fuel pump controller was duff

When: 24 Aug 2008 (Bank holiday weekend)
Where: Douglas, Isle of Man (visiting the Manx GP)
Rider: Tony Walker
Bike: 06 1200GS, 11000 miles (only owned the bike for two months)
Remedy: van to ferry, then home from Liverpool courtesy of Carole Nash recovery. New controller £85
Days holiday lost: two

When: 24 Aug 2008 (Bank holiday weekend)
Where: Taunton
Rider: Khanage
Bike: 05 1200GS
Remedy: recovered to CW in Dorchester
Cost: £112

When: 25 Aug 2008 (Bank Holiday Monday)
Where: A47 in Leics
Rider: Paula Ross
Bike: 06 1200GS, 24k miles.
Remedy: RAC to dealer, new controller fitted free-of-charge
Days lost: all afternoon on Monday then late to work Tuesday as had to org second part of relay to BMW

[Tim Cullis]

179 documented failures so far

2004: 7
2005: 11
2006: 26
2007: 50
2008: 85

A substantial number of these failures were in moving traffic and therefore potentially dangerous.

"I nearly died."
"Nearly wiped out by Dutch truck."
"Outside lane of M4."

Some were whilst people were on holiday and involved lost days or cutting their holidays short.

BMW Assist, "Oh, this happens all the time."
"I keep a load of spares in the boot. You should write to BMW about it."

BMW Customer Services (on failure complaints): "You have a warranty. What more do you want?"
"BMW does not recognise the problem you describe as an inherent design fault."

After some digging I've found that the F range models appear to have a different design
controller (1614 7 708 312) from the 1200GS and as yet I've not identified any failures
- F800S, F800ST
- F800GS, F650GS twin

The fuel pump controller from the 1200GS/GSA (1614 7 694 999 and subsequently
1614 7 719 844) is fitted across the R and K ranges, e.g.
- HP2 Enduro, Sport and Megamoto
- R1200GS and GSA
- R1200RT, R1200ST, R1200R, R1200S
- K1200R, K1200GT

There have been some reports of failures on the HP2, 1200RT, 1200ST but I've not yet found failure reports for the 1200R, 1200S or the K1200 range. What is it about the 1200GS that causes so many failures?

Tim

Originally Posted by Gipsy

While getting my bike fixed in Budapest, I happened to see a K1200R with its fuel tank off. The FPC is in a very 'sheltered' place compared to the 1200Gs and seemed to be mounted on a vertical surface. If water ingress is indeed a cause of failure this set would seem to make it less likely for water to pool and then trickle past the gasket.

Update: as of August the 1200GS/GSA FPC part number is said to be 1614 7 720 776

Please continue reporting any failures on this thread.

Tim

[jonnie comet]

Apologies if this info' has been posted elsewhere.

Try and see this week's MCN.....Page 13 headline

'BMW ADMITS QUALITY CONTROL ISSUES'

The article contains a number of quotes from Adrian Roderick (BMW UK general manager)

The gist of the article was that BMW were fully aware of the EWS and fuel pump controller problems on the R1200GS.
BMW would not be recalling 'bikes, but dealers would replace faulty components when the 'bikes were serviced.

The article concluded with...

'A BMW spokesman said dealers had now been told to contact customers and inform them of potential faults from September'

I had 2 go on my old bike Standard 1200 ST54HLY in 2005
Both at home recovered twice to Inverness.

[Mungrel]

Rider: Spanner Rash
2005 model 1200GS standard. **05 TLZ
Happened in Manchester in mid 2006. Had to get recovery to dealer on back of a tow truck.
0 days off work (used the car/tram for 2 days though, so there's the incidental costs!) Not to mention the local chavs chucking peanuts at me! And having to share public transport with the great unwashed.

Had a hell of a time with BMW UK as this was the 9th failure of parts in 8 months. Mostly electrical, including coils and a failed emitter ring.
Ended up doing a swap for an 1150GSA. (Whih never missed a beat in the next 20,000 miles)

Spanners

I've had 2 FPC failures.

1.
When: Summer 2006
Where: Front garden, Ealing, London
Name: N. Farrey
Bike: '05 R1200GS
Remedy: BMW Assist sourced an FPC from nearby colleague and replaced it.
Cost: Intended ride out aborted

2.
When: June 2008
Where: Brighton seafront
Name: N. Farrey
Bike: The same '05 R1200GS
Remedy:After 5 hours being mucked about, finally transported home. Next morning, transported to BMW Battersea where they replaced FPC - at my cost, despite protests. They promised to 'talk to head office about some goodwill recompense' - they never called back...
Cost:£160 and a very frayed temper.

Hi Tim.

My experience below:


- When did it happen? Saturday 22nd March 2008
- Where were you? Near Abergavenny Wales
- rider name Andy Lalor
- bike details (model and year) R1200GS 2005
- remedy - Breakdown recovery got me back home to Maidenhead as it was Easter weekend then took the bike to Vines in the following week. Vines replaced the unit which cost me about £95
- How many days work/holiday did you lose? I lost 2 days of holiday planned in Wales
- Were there any incidental costs? I had accommodation costs that I paid upfront for 3 nights away from home and had to go home after 1 night due ot the breakdown

I hope this is useful and thanks for taking up this challenge for all of us!

Regards

LSS

[Yonkyo]

I've also had a FPC failure.


When: June 2008

Where: Fast lane of M4 Near Chippenham

Name: Brian Pope

Bike: 2006 R1200GS - 16k miles

Remedy: BMW Assist returned bike to BRM, Bristol. Provided me with hire car. bike fixed and ready next day.

Cost: Nil...luckily

[DodgyGeeSer]

- May 2008
- M50, Dublin, Ireland
- Gary Condon
- R1200GS 2005
- After reading threads, bought replacement fuel pump relay, and replaced.
- Lost 2 Hours of work
- Cost of replacement fuel pump relay - 118 euro.
Comment: On the way to work, after leaving motorway, at busy roundabout junction. Bike stalled, and had to push bike off motorway off-ramp in the middle of heavy rush-hour traffic.

[paulB]

- When did it happen? = January 2008
- Where were you? = working late in Guildford
- rider name = Paul Burt
- bike details (model and year) = R1200GS April 2005
- remedy = RAC b***dy useless, train home, car trip to Bahnstormer to buy new contoller then late to work and fit it
- How many days work/holiday did you lose? = A half day
- Were there any incidental costs? = train, wife's time to drive me to work

In April it wouldn't start after riding through heavy, prolonged rain so had to clean out fuel pump controller contacts. Crap design and weather protection. Good luck getting proper recognition of the issue.

Yip had the very same problem with my 2004 GS back in July of this year!

- When did it happen?: July 2008

- Where were you?: en route to isle of skye one quarter of the way through a 1,800 mile tour!- rider name

- bike details (model and year): 2004 R1220 GS

- remedy: electrical bypass fix on side of the road using direct feed from fog lamp loom. Toured for another 2 days before calling into a BMW dealership to collect new controller & fit whilst still touring!

- How many days work/holiday did you lose? None, just had a good friend who happens to be a BMW mechanic & talked me through the fix or it was onto the back of an AA van for me!

- Were there any incidental costs? Just the overpriced new controller unit