Fuel pump controller workaround

[Wapping]

Hi
is anyone making a FPC bypass lead in the UK if so how much I am going on the ride to Croatia 09 and thought it might be worth getting one.

Thanks
Eddie

Why not:

(a) Find out if your FPC is one of the older types (which may fail) or one of the new type (which may not).

(b) Simply buy a spare controller to take. It works properly out of the box and saves fiddling about.

(c) Failing (a) and (b) make one yourself, following the directions in the sticky.

 

[GSEddie]

Wapping
Just phoned the dealers and They say it might it might not so decided to get a spare FPC just incase only £67.54 like you say it will save fiddling about.

Thanks
Eddie

 

[Malcvtr]

I posted this in vendors of inovations section but i will put it here as well in case the info might be usefull for any one making a bypass lead.
The Tyco number for the blue 2 pin is 828816-1 a search returned this item, only 60 pence and looks the same just in black from UK supplier as well http://www.automotivewiringsystems.c...1-828816-1.htm

Thanks for this. Being no expert on electrical stuff, can you confirm this is definitely the right connector?

I've got an Optimate extension lead and the fused lead to the battery, so I intend to cut the plug off one end of the extension lead, attach this plug instead and bingo I've got my made up get-you-home lead. But it'll all be screwed if this just looks the same, but isn't...

Cheers

 

[Wapping]

Thanks for this. Being no expert on electrical stuff, can you confirm this is definitely the right connector?

I've got an Optimate extension lead and the fused lead to the battery, so I intend to cut the plug off one end of the extension lead, attach this plug instead and bingo I've got my made up get-you-home lead. But it'll all be screwed if this just looks the same, but isn't...

Cheers

The workaround is for an emergency only, to get you home.

The best solutions are:

(a) To check whether the controller is of the old type (ie meaning it may well fail, at some point)

(b) Of the new type (ie meaning it may well not fail)

(c) Go to BuMW and buy a spare. Then, if a failure occurs, you will be ready to go with no great drama and concerns over plugs or anything else.

Either way, you will need the right tools to get the failed controller out. Without which you are no better off.

 

[Malcvtr]

Thanks Wapping. Mine's a March 06, so I guess it's the old type. As I'm riding to the south of France in August, I guess I'd better bite the bullet and buy the spare... But I'll check with Balderston's first about the type I've got.

The thing I liked about the get you home fix was that it was re-usable, whereas the spare might still fail.

 

[Paul Wakefield]

Or, if you just want to protect your holiday rather than having a permanent spare, ask your dealer if they will lend you one.

 

[AndyW]

Thanks for this. Being no expert on electrical stuff, can you confirm this is definitely the right connector?

I've got an Optimate extension lead and the fused lead to the battery, so I intend to cut the plug off one end of the extension lead, attach this plug instead and bingo I've got my made up get-you-home lead. But it'll all be screwed if this just looks the same, but isn't...

Cheers

I posted this in vendors of inovations section but i will put it here as well in case the info might be usefull for any one making a bypass lead.
The Tyco number for the blue 2 pin is 828816-1 a search returned this item, only 60 pence and looks the same just in black from UK supplier as well http://www.automotivewiringsystems.c...1-828816-1.htm

Fixed link:
http://www.automotivewiringsystems.com/3-52-tyco-connector-1-828816-1.htm

Now if we can find a part number for a connector that will pair with the black 'power in' connector topside of the Controller...

....a nice 'stubby' bypass lead would be possible like this, quick and easy to use:

(found this on an Italian site where I've posted asking for info on the black connector)

 

[AndyW]

....sorted, see:
Really neat Fuel Pump Controller bypass

 

[Malcvtr]

Fixed link:
http://www.automotivewiringsystems.com/3-52-tyco-connector-1-828816-1.htm

Have you managed to order a plug successfully from this site? I haven't because don't think they're interested in selling just one - one thousand, maybe...

Thanks for the link anyway

 

[Bryn]

Just while we're on the subject... I checked a workmates 05 1200 and showed him how to find the FPC.. taking the vented cover off revealed it was sitting in a nice puddle of water, which could or could not be the problem...

So having popped into my local neighbourhood BMW dealers I was told that the FPC doesn't run hot and it can't do any harm covering up the vents on the black cover

There's still venting at the back where the wiring/tubes go in

 

[mark2jag]

we all need to club together (but not seals)

... There's a bit of food for thought, and I appreciate Robin's and Richard's (Wapping) suggestions regarding safety and the K.I.S.S approach.

... I'll have a look again when I'm back in UK in a week(ish)

... Anybody who believes that a collective approach is worth pursuing note your interest down here (assuming Mods don't mind)
... Given sufficient interest a simple draft can be winged Bracknell way in due course.

... Unless YOU have a better idea

Bloody good idea, I live minutes away from BMW Bracknell

and id be so happy to drop it through their door or some such idea, bearing in mind probs with my 1200, so far (bought on July the 1st.)

 

[El-Stoopido]

FPC Failure

Well I think it has just happened to me! Had to leave my bike about 5 miles from home in a dodgy area of town (no RAC cover) and got the current Mrs El-Stoopido to pick me up. I'll call BMW in the morning and see if they've got a new FPC in stock. If not I'll butcher the old FPC and attempt to make a "get home lead" (that's if the bike's still there).

Pretty shocking for a 3 year old 10 grand bike though!

 

[SMcGirr]

Me too

Had my 07 GS in for service this morning, took it home, washed it (with a bucket, not even a hose) went to start and although it caught for a few seconds it just died out. Rang Williams and asked if it could be the FPC and advised to ring BMW assist. Guy just turned up and lo and behold : its the FPC. He says taht the newer powder coated one is better sealed and he hasnt known a new one to fail.

He has gone to Williams to pick a new one up.

Am I the only one then to have had both the EWS and FPC fail ?

SMcGirr

 

[El-Stoopido]

Well, in her 3 year life my GS has had a failed battery (warrenty), replaced timing belt cover (goodwill gesture after warrenty run out, but the labour charges and replacement oil were'nt), failed brake switch (pricy), and now this.

I honestly thought when I bought this bike I was paying a premium price for a quality machine I could keep for years and travel the world on. Instead it's turned into a black hole for money and I've totally lost confidence in it as it's so unreliable!

Can anyone list all the other likely problems I'm going to have to deal with?

 

[AberdeenAngus]

Guys, we need to be careful here, the pump electronics is there for a reason, the way it works is it applies a PWM, (pulse width modulated), voltage signal to the pump. By 'varying' the voltage to the pump the control unit has infinate 'control' over how fast the pump runs, i.e. if the load demand is low, it will run the pump at a low speed with a lower voltage, and vice-versa.

By putting permanent battery voltage to the pump via the pto socket, we run the risk of shortening the pump life, and the pump being directly supplied will no longer be controlled by the ECU, this means the ecu cannot turn off the pump if it needs to!

Not wanting to p*ss on anyones fire, but i think we do need to approach this with 'caution', especially bikes that are still in warranty?

Just the thoughts of a 'simple' tosser!

Sorry but PWM doesn't work that way.
The voltage remains the same, it's just turned on and off really fast so you can reduce the speed of the pump motor without losing torque.
I refuse to believe that BMW would fit a pump motor that wasn't rated for continuous running.
The regulator is there to reduce load on the fuel pump when not needed and hence save fuel.
As a roadside fix, I see nothing wrong in direct wiring the pump motor to the battery.

 

[AberdeenAngus]

I'd be surprised if the capacitor failed, they're normally fairly reliable. The big power transistor would be the likely culprit for overheating, if anything was. Not so sure about what would happen with water ingress.

If the capacitor trick does not work, if you want to send me the board I will get the transistor off and check it, also I can try to work out a circuit diagram, if no one else has bothered to do so, I've not checked.

Can you read the numbers on the 8 pin ic and the black devices on the other side of the board?

Capacitors often give problems, if they get hot !
All electrolytic capacitors are temperature rated. They have an expected life at that temperature. This expected life falls off quickly the hotter they get above their rating. During normal use capacitors don't really get hot therefore I very much doubt the heatsink is there for a capacitor. If it's a failed capacitor, I think it more likely to be a symptom rather than a cause, therefore you can expect it to go again soon.

 

[walti]

Hmmm....

New fuel pump controller purchased and fitted (yes really it's the second one!)

New one is a pretty black colour which is supposedly more corrosion resistant!

 

[babu]

Can anyone list all the other likely problems I'm going to have to deal with?

Oh man... Let's see... In no particular order:

Your new battery will fail just as the original one. They're all useless. Switch to Odyssey.

Your windscreen will rattle.

You will experience an oil leak between the gearbox and clutch.

Your front breaks will squeak and rattle.

Your new fuel pump controller will fail just as the original one.

The antenna thing for the key will fail.

Your topbox will crack and fall off.

For a start.

I find it incomprehensible that the germans managed to engineer this fantastic bike and yet seem unable to produce it.

 

[El-Stoopido]

Oh man... Let's see... In no particular order:

Your new battery will fail just as the original one. They're all useless. Switch to Odyssey.

Your windscreen will rattle.

You will experience an oil leak between the gearbox and clutch.

Your front breaks will squeak and rattle.

Your new fuel pump controller will fail just as the original one.

The antenna thing for the key will fail.

Your topbox will crack and fall off.

For a start.

I find it incomprehensible that the germans managed to engineer this fantastic bike and yet seem unable to produce it.

I need to get rid of this nightmare! I just took a call from the dealer (John Clarkes, Aberdeen), apart from the FPC, the ABS module has gone, which will cost £1100 for the replacement part alone, not to mention BMW's outrageous workshop costs.

I simply can't afford to run this bike.

I've been riding bikes for the past 25 years, and I have never owned such an unreliable machine.

Great bike to ride, very poor quality.

Rant over, anyone interested in a 2006 GS, 10,500 miles on the clock. Summer use only, garaged all year round?

 

[AberdeenAngus]

I have an 04 GS. Fuel pump went on it last year, due to water ingress. New unit was sent in the post from CW Motorcycles with updated o-ring. To stop the swimming pool filling up again i fitted a oil lamp wick,from the deepest part of the pool, under the cover and cable tied down part of the side cover frame. Now when out in the rain or when washed down, pool is empty in about 30 seconds. Can't drown unless in water! Works for me.