Dead fuel-pump controllers: Appeal for info.

Nick V

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Hi, all!
This is an appeal to the entire UKGSer community, particularly those who've had the misfortune of a failed fuel-pump controller, or have friends who have.

I'm in the middle of writing an article which details a workshop repair for a non-functional FPC. What I need is information on which components of the controller fail, and with what relative frequency. If said info can be acccompanied by a couple of pics showing the failed components, so much the better!

If you have a dead FPC, I need to ask a huge favour. I need pictures of the innards; all you have to do is:
  1. Turn the FPC so the blue terminal faces upward.
  2. Use a small flat screwdriver (approx. 2mm) to 'peel' back the epoxy 'potting' that covers the circuit board. Make sure the entire board is exposed.
  3. Set your camera or mobile-phone camera to the 'Macro' setting. Take one or two clear piccies of the circuit board, making sure all damaged components are in clear focus.
  4. Post said piccies here. ;)

Any help in this regard would be greatly appreciated! Any and all peeps who help out will be credited in the finished article.

Thanks, guys! :thumb
 
Isn't this all a bit late?

The incidence of failures has dropped to all but zero, so the numbers of failed units that could be opened up for inspection will be similarly small.

The incidence is statistically difficult. I had one failure on one GS, none on the earlier edition other. I later sold the bike that had suffered the failure to a friend, who has had no problem. So, I would report just one failure occurring out of two bikes, whilst my friend would report no failures.


Now, if you can turn your mind to clutch / gearbox / gear lever issues......
 
Not worth repairing. If you're worried and have a silver one, buy a black one and forget about it.
They don't cost much.
 
Not worth repairing. If you're worried and have a silver one, buy a black one and forget about it.
They don't cost much.

Black one's fuck-up too......actually that was Autumn 2011 as I arrived at the Horizon's do near Bath... best pick up a spare.... it's worked for more than 2 years....

:beerjug:
 
Thought they are sopposed to be ok if you keep em clear of debris and standing water,just keep em smothered in AFC50,MINES DONE 23000MLS a lot of them in pissing down conditions ,always kept the FPC clean and coated in AFC50 and no probs. Yet.
 
Mine failed in Australia somewhere just outside Bumfucksville, WA. No mobile phone signal and a long way from the Perth metropolitan area. Thought the local six fingered banjo players might get me but thankfully I made it out alive thanks to a rider with one bar on his phone allowing me to get help, then hot wired the fuel pump directly to the battery to get it running and prove the cause of breakdown. Bought a replacement FPC a week later then cut open the failed unit to find a blown capacitor, used the old blue connector to make an emergency bypass cable. The FPC heat sink fins seem designed to cool the capacitor.
 
Isn't this all a bit late?

The incidence of failures has dropped to all but zero, so the numbers of failed units that could be opened up for inspection will be similarly small.

Now, if you can turn your mind to clutch / gearbox / gear lever issues......

Are you joking? If so, it's not very funny - not when anyone is able to look at the 'Failed FPC numbers' thread and realize that the problem is ongoing as of February 2014.
Frankly, I'm wondering what motivated you to say this.

Let me explain my approach.
I don't care about statistics. I've concerned myself with ways and means of eliminating, or at least drastically reducing, a clear and present dangerous possibility that an FPC might fail. Possibly at the moment a rider's trying to clear a known high-crime area or may have misjudged the rate of closure to head-on traffic, while trying to overtake an HGV.
You are able to picture the possible consequences of both scenarios, yes?

In the face of this, my goal is that the article I'm trying to write will benefit those with failed FPCs in two ways: giving them recourse to an emergency roadside repair that doesn't require robbing an FPC for bits. The rationale behind this is the basis for my second point: being able to repair the failed FPC to better-than-new condition so that it doesn't fail again.
In order to do this, I require constructive input. Input to which I currently have no access other than through sites like this one.

If you'd still like to speak so condescendingly in the face of that, feel free. But I suspect that an awful lot of people who've experienced FPC failure will not be joining you.

Black one's fuck-up too......actually that was Autumn 2011 as I arrived at the Horizon's do near Bath... best pick up a spare.... it's worked for more than 2 years.... :beerjug:

Mine failed in Australia somewhere just outside Bumfucksville, WA. No mobile phone signal and a long way from the Perth metropolitan area. Thought the local six fingered banjo players might get me but thankfully I made it out alive thanks to a rider with one bar on his phone allowing me to get help, then hot wired the fuel pump directly to the battery to get it running and prove the cause of breakdown. Bought a replacement FPC a week later then cut open the failed unit to find a blown capacitor, used the old blue connector to make an emergency bypass cable. The FPC heat sink fins seem designed to cool the capacitor.

What you gents said.
The point isn't that it 'isn't likely' to happen. The point is that it happens.

Puk, do you any close-up pics of the blown component you might share?
 
Are you joking? If so, it's not very funny....

I don't care about statistics. I've concerned myself with ways and means of eliminating, or at least drastically reducing, a clear and present dangerous possibility that an FPC might fail. Possibly at the moment a rider's trying to clear a known high-crime area or may have misjudged the rate of closure to head-on traffic, while trying to overtake an HGV.
You are able to picture the possible consequences of both scenarios, yes?

But I suspect that an awful lot of people who've experienced FPC failure will not be joining you

Clear and present? Are you some sort of faux CIA operative, getting tech?

You asked for statistics (relative frequency) and refer in your post to something that is nothing but meaningless lists of bods recording a failure. Then you tell us you don't care about statistics. Make your mind up, chum.

My own FPC occurred in the known high crime area of Tower Hamlets, London E1. I often give thanks to the Almighty (and offer regular candles to St Jude) that I and my bike escaped.

Actually, that last bit is not entirely true. It did indeed occur in the clear and present known high crime area of Tower Hamlets, London E1 which (though being London's poorest borough) is not downtown Soweto when the necklace season is in full swing, nor is it pastoral rural England, either. I know this, as I live, clear and present, in London E1.

Being of stout character and employing the best British stoical traditions, I found it best not to sit around imagining all sorts of dire possible consequences; instead I got on a mended it. Not once did I imagine what might have happened, any more than I spend time imagining that a giant bat might swoop down and carry me off to a remote crater on the moon. I did though publish the popular workaround, should anyone ever find themselves stranded outside of the clear and present comfort zone of Tesco's car park on a Saturday morning.

Please don't try to make a drama out of everything; there's enough worry in the world without you heaping more on top. There is an entire thread just starting where bods are getting increasingly worried about getting tail-ended in rainy weather, of which we have a surfeit just at the moment. Of course they don't know anyone who has ever been significantly injured by being tail-ended on a motorway but the sheer sudden realisation that it might happen is sending them scurrying for the hi-viz LED's. The same fellows will probably eschew the wearing of a hi-viz jacket as an infringement of their rights.... But lights? Boy, that's another matter entirely. Lights front, lights back... It's the future!
 
Yes some do get all heat up about dayglo, daylights and ACF-50 on the tyres. But that doesnt make a how to fix something a pointless exercise. Its Nick's time FGS.

Let the guy ask for his pictures. The information might help someone in need. We also dont know how long the updated FPCs will last so this could be a handy resource in years to come.

BUT I second the request for info about clutch changes and clutch hydraulics cylinder fixes. Also how to take off the front engine cover for repainting. Certainly its old hat but as time drags along ever more bikes are suffering from salt rash.
 
Clear and present? Are you some sort of faux CIA operative, getting tech?

You asked for statistics (relative frequency) and refer in your post to something that is nothing but meaningless lists of bods recording a failure. Then you tell us you don't care about statistics. Make your mind up, chum.

My own FPC occurred in the known high crime area of Tower Hamlets, London E1. I often give thanks to the Almighty (and offer regular candles to St Jude) that I and my bike escaped.

Actually, that last bit is not entirely true. It did indeed occur in the clear and present known high crime area of Tower Hamlets, London E1 which (though being London's poorest borough) is not downtown Soweto when the necklace season is in full swing, nor is it pastoral rural England, either. I know this, as I live, clear and present, in London E1.

Being of stout character and employing the best British stoical traditions, I found it best not to sit around imagining all sorts of dire possible consequences; instead I got on a mended it. Not once did I imagine what might have happened, any more than I spend time imagining that a giant bat might swoop down and carry me off to a remote crater on the moon. I did though publish the popular workaround, should anyone ever find themselves stranded outside of the clear and present comfort zone of Tesco's car park on a Saturday morning.

Please don't try to make a drama out of everything; there's enough worry in the world without you heaping more on top. There is an entire thread just starting where bods are getting increasingly worried about getting tail-ended in rainy weather, of which we have a surfeit just at the moment. Of course they don't know anyone who has ever been significantly injured by being tail-ended on a motorway but the sheer sudden realisation that it might happen is sending them scurrying for the hi-viz LED's. The same fellows will probably eschew the wearing of a hi-viz jacket as an infringement of their rights.... But lights? Boy, that's another matter entirely. Lights front, lights back... It's the future!

Should I take your prayers to the patron saint of desperate cases and lost causes as a tacit admission?

My apologies - I failed to elaborate that I don't care for YOUR application of statistics.
Frankly, your approach to the whole problem reminds me of an ANC politicians': "It's not my problem, therefore there is no problem". What amazes me is how you hoped to get away with a comment as preposterous as "The incidence of failures has dropped to all but zero" when it plainly isn't true!

There will always be two different schools of thought: one which tries to solve issues with unwarranted faith, and money ("The answer is yet another brand-new FPC"), in opposition to one which investigates failures, identifies them by name, and eliminates them.
Blind hope and denialism has gotten paying customers - and BMW Motorrad - nowhere. Proof of that, if proof were needed, is that the first approach above is obviously not working.

I'm trying my best to formulate a solution here, with intent to help people a) get home, and b) take a pro-active approach by eliminating the root cause of the FPC bug. What do you hope to gain by belittling that, and bringing this crab mentality out to play?
What's going on in your mind, and what is your real game?

If you can't offer any constructive assistance towards a solution, I respectfully suggest that some soul-searching is in order, and ask that you stay out of this thread.

BUT I second the request for info about clutch changes and clutch hydraulics cylinder fixes. Also how to take off the front engine cover for repainting. Certainly its old hat but as time drags along ever more bikes are suffering from salt rash.

Bendy, I'll see what I can do in the near/mid future.
Odd how 'national' priorities differ. Corroded front engine covers are unheard-of here, as we don't use salt on our roads. The most you'll see is a few isolated stone chips.
 
Nick, your intentions seem good, but 'flogging a dead horse', 'closing the stable door after the horse has bolted' and 'You've missed the boat, bikermate' all spring to mind.

I mean that in a positive way by the way......and although I've never owned a 1200, I've been carrying the well known, well documented and absolutely free bypass kit as detailed on this very forum since 2006, amongst my spares kit on my 1150.

You're picking a rather odd, well understood and well solved problem to get involved in :comfort

As the dragons would say......."and for that reason, I can't invest in your idea and I'm out"
 
i tried to think of saying the same thing nicely but failed,fanums reply is spot on imo,its bin done and dusted,nothing to see here,move along etc.
 
Upbeat tone appreciated, gents.

But if this is such a waste of time then why, to this day, do BMW refuse to totally redesign the thing and provide replacement parts free of charge?

And if this is such a waste of time then why, after eleven years of development, are new-and-improved FPCs still failing?

although I've never owned a 1200, I've been carrying the well known, well documented and absolutely free bypass kit as detailed on this very forum since 2006, amongst my spares kit on my 1150.

Dead weight on an Oilhead, innit? Those bikes use a constant-current fuel pump with return line. There is no PWM hardware.
 
Upbeat tone appreciated, gents.

But if this is such a waste of time then why, to this day, do BMW refuse to totally redesign the thing and provide replacement parts free of charge?

And if this is such a waste of time then why, after eleven years of development, are new-and-improved FPCs still failing?



Dead weight on an Oilhead, innit? Those bikes use a constant-current fuel pump with return line. There is no PWM hardware.

I didn't carry it for MY bike ;)
 
Dead weight on an Oilhead, innit? Those bikes use a constant-current fuel pump with return line. There is no PWM hardware.

Mystic Meg, says:

I predict where this is heading.

BGT: In case a 1200 I am travelling with has FPC failure. I make the temporary fix, we carry on.

Nick V: They should not fail, it needs to be addressed at source by BMW.
 
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Nick V, yes occasional FPC failures are still being reported in late 2013 and early 2014. However, instead of concentrating on the year when the fault manifests itself, look instead at the year of the bike's registration.

What you are probably seeing to today is nothing more than the older models washing their way through the system. That and bods whose bikes just stop, where the rider assumes that it's FPC failure, when it's not. There are several threads where the assumption is proved to be very wrong.
 
I am with Fanum I am afraid and although Wapping didn't mince his words he has a point. In defence of that point I give you the almost complete lack of support for your idea. 8 years ago you would have been the man and a hero of many but it's pretty rare now. Even the thread you linked to has very few actual failure posts in it for the last couple of years. The newer bikes (2008 on) not only changed the FPC but also the tank shape so the water didn't collect.

Top marks for effort and thinking of the community but I fear that boat has sailed.
 


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