Fuel pump controller workaround

[MikeP]

My controller was not corroded and was not wet or dirty. While I am not an electronics expert, I reckon there is a chance that the reason for at least some of the failures is overheating of the controller.

As the unit soaks up the excess 20% power it would have to release it as heat? If it cannot release the heat fast enough then bingo there goes another one.

Someone (can't remember who) said the same thing in conversation not very long ago.

Maybe they are meant to be water-cooled and the failure of 'submerged' ones is not related to the water ingress?

Before anyone goes much further, somehow, someone needs to determine to exact cause of the failure; water, heat or just poor quality component?

 

[Thunder]

(1) Does anyone know if the newer ‘08 bikes have been significantly altered? If so, BuMW probably know about the problem, though they are unlikely to admit it.

(2) Does it look like the alteration is retrofittable, or is it some complicated moulding, different beak, different controller, making it impossible?

The 2008 GS has had significant changes to the fuel tank and the relay position is now angled to prevent water pooling.

It's not something that will be retrottable to previous bikes (well it could but would cost a fortune) but is an indication that BMW are aware their is a problem with the earlier models.

The 2008 GSA has not had as many changes as the GS, as far as I'm aware the tank is the same as earlier models.

 

[John Armstrong]

From memory, your 08 GSA fuel pump controller area looks to be at more of an angle than my 07 GSA. Covered the plugs and wiring in ACF50 though, just in case, even though I've not had a failure Said touching wood, fingers crossed

 

[Thunder]

From memory, your 08 GSA fuel pump controller area looks to be at more of an angle than my 07 GSA. Covered the plugs and wiring in ACF50 though, just in case, even though I've not had a failure Said touching wood, fingers crossed

John

That's not the 08 GSA

 

[John Armstrong]

John

That's not the 08 GSA

 

[deaninkl]

From memory, your 08 GSA fuel pump controller area looks to be at more of an angle than my 07 GSA. Covered the plugs and wiring in ACF50 though, just in case, even though I've not had a failure Said touching wood, fingers crossed

John, I have not seen ACF 50 out here.. is it similar to WD40?

 

[John Armstrong]

John, I have not seen ACF 50 out here.. is it similar to WD40?

Similar but better.

The ACF50 AFAIK was designed around aircraft and the corrosion problems caused by disimilar metal and galvanic corrosion as the aluminium skins and rivets / fasteners are invariably different materials. Plus the method of construction using frames and stringers makes water / fuel / "blue" water traps almost inevitable. To counter this you need to carry out regular inspections and use a long term heavy duty protection.

ACF 50 site is here: http://www.acf-50.co.uk/

If you're interested in the stuff, NN does it mail order, but might be slightly expensive postage to you in which case if you know any heavy aircraft maintenance people (buzz word is CPCP) they might be able to guide towards an alternative.

 

[deaninkl]

thanks for that John, I have the Boeing rep living opposite me... ride a nice 93 heritage softail, he should be able to steer me in the rght direction.

 

[John Armstrong]

Glad to be of help, another name I can remember is Dinatrol, but might want to read this article first http://www.aviationtoday.com/am/issue/productfocus/18239.html

 

[Davy F]

I sprayed my pump controller in WaxOil. I also duck taped over the slots in the cover, tho' I doubt that'll stop water getting in and may even cause condensation. But so far, it's stayed nice and dry.

 

[harry]

I sprayed my pump controller in WaxOil. I also duck taped over the slots in the cover, tho' I doubt that'll stop water getting in and may even cause condensation. But so far, it's stayed nice and dry.

Can I ask how long you have had the cover slots taped up?
Have you run it for long periods in warm weather taped up?
I wonder if anyone has felt the controller to see how warm/hot it gets on a longer run?

 

[Magwych]

Harry,

I did a similar mod, filling the slots with black silicone @ 3,500 miles after mine failed.

30,000 UK miles and a Moto-Morocco trip later there had been no problems with it either failing due to water or heat. And it ws Damn Hot between Foum Zqid and Zagora...

 

[harry]

Harry,

I did a similar mod, filling the slots with black silicone @ 3,500 miles after mine failed.

30,000 UK miles and a Moto-Morocco trip later there had been no problems with it either failing due to water or heat. And it ws Damn Hot between Foum Zqid and Zagora...

Thanks for that CB.....I think I'll go ahead and do mine.

 

[Davy F]

Can I ask how long you have had the cover slots taped up?

About 10 months.

Have you run it for long periods in warm weather taped up?

We haven't had any since April '07

 

[Wapping]

The 2008 GS has had significant changes to the fuel tank and the relay position is now angled to prevent water pooling.

It's not something that will be retrottable to previous bikes (well it could but would cost a fortune) but is an indication that BMW are aware their is a problem with the earlier models.

The 2008 GSA has not had as many changes as the GS, as far as I'm aware the tank is the same as earlier models.

Good clear picture...thanks.

 

[bustupbiker]

I can't see my pic's at the moment but from memory:

Blue was neutral.

White was positive.

Robin's 'second hand' plug had a white lead and a blue lead. Mine was a yellow (I think) and a blue - maybe his had just faded or because mine is a GSA and his, I think, a vanilla 1200GS? Either way, blue was neutral.

Thank you kind Sir

 

[bustupbiker]

So does any body else have a spare dead control unit they can let me have please? Then i too can make it through the storm, should it hit me....

 

[Paul S]

Picture of the 08 GSA fuel pump - definetely still collects water

 

[Wapping]

I was in BuMW Battersea this evening, getting my rear end fixed.

Whilst there I relieved them of one controller in a nice little box.

One question, for those who have bought one, too.

There is a small gasket (green in colour) on the bike and shown on the parts fiche.

I asked the little monkey, "Does it come with the gasket?" "Oh, yes" (a la the Churchill dog).

When I got home.....no gasket.

Simple question: Should there be a gasket with it, or is it truly a separate part?

===

I didn't do very well really.

I bought a new wing mirror as well...that was wrong. Screw thread on the bottom of the stem, mine is smooth and clamps. So I will be going back anyway....

 

[Wapping]

Picture of the 08 GSA fuel pump - definetely still collects water

Thanks, another clear picture.

I see that BuMW have tidied up the wire cabling though...