Fuel Pump Flange leak - Grrrrr!

[Kersidan]

R1200GS 04MY 55Plate 2006 32K miles - On my last ride to France last year I noticed these leak marks on left side of bike.


I got home cleaned it off and put the bike away for the winter. Off to Portugal in May so yesterday I thought I'd better get her out give her a run and find out if the leak was still there. Within a mile or so I could see drips coming off of the lower side panel below the tank. Further investigation revealed the dreaded fuel pump flange had hair line cracks in the boss that the QR line connects to from the high pressure side of the pump. And this is with my bike having had the BMW recall to have the metal collar fitted to the flange! I couldn't be asked to take this up with BMW so I contacted MotoWorks and have a used flange but good flange being sent to me.

Question for the learned of this forum - Would you use any jointing compound or PTFE tape around the QR union that screws into the flange or just assemble 'o natural'? And I assume that you shouldn't do the QR up too tight as it is has a tapered thread that effectively puts pressure on the moulded flange boss and cracks it. I've attached some pics that should help to explain.

Thanks for any advice.

 

[TLSgazza]

Contact your dealer again. There was a recall on these because of them cracking iirc. Should be fixed again for free.

 

[Kersidan]

Contact your dealer again. There was a recall on these because of them cracking iirc. Should be fixed again for free.

I did think of that but I couldn't face the hassle of getting the bike there, waiting for a decision etc etc. For a few ££ I've got a hopeful solution arriving from MotoWorks on Friday and then I'll be back on the road. If this solution doesn't work then I'll be onto BMW quick.

 

[DrFarkoff]

I did think of that but I couldn't face the hassle of getting the bike there, waiting for a decision etc etc. For a few ££ I've got a hopeful solution arriving from MotorWorks on Friday and then I'll be back on the road. If this solution doesn't work then I'll be onto BMW quick.

Its as easy as ringing any BMW Motorrad Dealer and asking for Service dept and having your frame number to hand and tell them you want to check your vehicle for recalls

Its a Safety recall You should really have had a letter about it

I had the same thing only it was like a water pistol squirt of fuel Quite dodgy to be honest with Fuel and fast moving air vapourising it

I had a video somewhere but can;t find it now

And in answer about the thread seal I would use liquid form but the new one comes with the fitting attached except the Pump relay, it's seal and the two screws

Edit Found video ....

 

[Kersidan]

I called my local (ish) BMW dealer and they obviously need to see the bike before they can comment if it's covered under a recall/warranty. They can't pick the bike up till 10th April so 2 weeks wait and then can't comment on any repair time...... Plus the cost of collection is at my cost, I forgot to ask how much but I'm sure it won't be cheap. So I have a good used part on it's way from MotoWorks that will get me back on the road in a day or so. A dilemma I know but I think I'll go the later route as the bikes stripped down and ready for the used part. If it goes again in a year or so then it's straight into BMW.

I'll update as and when and thanks for your valued views.

 

[DrFarkoff]

Sheesh Thats weird they should just put your VIN into the system and it will show the recalls and show whether or not they have been done and you don;t have to pay for the items

on the early bikes there was the Fuel pump flange, the rear wheel flange Brake Line check Speed sensor wire routing check

Perhaps yours has already had that recall done???

 

[Kersidan]

Sheesh Thats weird they should just put your VIN into the system and it will show the recalls and show whether or not they have been done and you don;t have to pay for the items

on the early bikes there was the Fuel pump flange, the rear wheel flange Brake Line check Speed sensor wire routing check

Perhaps yours has already had that recall done???

Yes, I believe the recall re fuel pump flange has been done, this being the metal collar round the flange (you can see this on one of my photos). This collar as AFAIK is the original recall fix unless others know otherwise. Maybe they have another fix now? So getting it to BMW and waiting for an outcome is a right PITA whereas I can fix it and get it back on the road in a day or so. It's 13 years old, a great bike and it does my European tours but its nowhere 'new' so some good home fixes are the way to go for now..... hopefully.

 

[DrFarkoff]

Did you check for where the leak was coming from ??

I wonder is it perished O rings on the connectors?

Apologies for not suggesting that sooner!

Yes, I believe the recall re fuel pump flange has been done, this being the metal collar round the flange (you can see this on one of my photos). This collar as AFAIK is the original recall fix unless others know otherwise. Maybe they have another fix now? So getting it to BMW and waiting for an outcome is a right PITA whereas I can fix it and get it back on the road in a day or so. It's 13 years old, a great bike and it does my European tours but its nowhere 'new' so some good home fixes are the way to go for now..... hopefully.

 

[Kersidan]

Checked everything else, here's a photo of the cracks in the flange, with the recall collar removed. I've got a new O ring for the male part of the connector coming from MotoWorks for good measure.

 

[DrFarkoff]

Hope it fixes everything for you

almost looks like that flange outlet was inserted too far doesn't ?

Must check mine

 

[Kersidan]

Used part arrived from MW's today. Surprisingly it was a complete pump assembly so all I had to do was fit my FPC and install it and she fired up straight away. NO LEAKS!! The new assembly didn't have the recall modification (metal collar) so I used my old one. It was a VERY tight fit and in the end I heated it up and sort of heat welded it on. Fired up again and still no leaks. All back together and have been for a test run in the lovely weather. Now going to do my yearly fluids service.

 

[Bendy toy]

Mine cracked like that before the fuel pump recall came about. I made a tight fit steel backing ring for the female stub and refitted the hose connector. All has been fine for so long I had forgotten all about it.

Note to anyone refitting the tank access covers -

Grease the inside of the seal rubber and the outside of the cover body. The tank side of the seal rubber must be bone dry. The pump will then slide into place without dislodging the seal.
Always check the seal top edge is visible all around (with a mirror) before screwing the retaining ring down.

If you get it wrong, you won't find out until the tank is filled with fuel and by then it's just a tad late.