Just When I was Being Smug...

[Magwych]

Got up extra early thismorning because I had to get to Battersea to drop my GS off for its 12,000 mile servce before going to work.

Was 16 miles up the M20 when engine started to splutter and cut in and out . Up until this point I have not had a single problem and have been guilty of a couple of smug "No probs here.." posts.

Called BMW Assist, who turned out within the hour ! My first thought on seing teh 3series estate was that there was no room in the back of one of those for a trailer, so this was going to be a long day of being passed form technician to pick up truck to dealer. Howeevr, technician was clucthing a polythene bag when he stepped out of car, aske dme to confirm the symtoms, then immediately stipped out the fule pump resistor pack and replaced it with the new one form his bag. The only contenst of which were the new pack and a seal for the fuel pump ring - not needed.

The old fuel pump resistor pack resembled a very old lump of stilton that had fallen behind a fridge for a few years, and the bike is only 6 months old

Apparently this is a "common fault"; the replacement pack was in fact the only replacement part the Assist guys carry.

Cause of the problem is the cooling holes in the cover allow rainwater to enter the fuel pumpt area, and it cannot escape. Result is the resistor pack sits in a puddle of water until its own heat evaporates the puddle.

Bike is running perfectly again and I am working very late to make up for lost time ..

Worthwhile lifting teh cover and checking the state of this from time to time ?

 

[(RIP) Bin Ridin]

Good you got going so quickly!
Will check mine, I thought this was cured by the o-ring recall ?

 

[Magwych]

The pack is on top of the fuel pump cover and exposed to the elements, although I did find it hard to see how the furr on the outside could affact the contents on the inside.

There were definite signs of the crud starting to seep past the seaing ring on the base though. I was also intersted in a very sharo kink in one of the wires that led off down to the pump itself; but not enough to investigate it any further for breakage ...I was just happy that the fault could be pinpointed and fixed relatively painlessly.

 

[Timolgra]

Called BMW Assist, who turned out within the hour ! QUOTE]

Practice makes perfect

 

[Clive]

Apparently this is a "common fault"; the replacement pack was in fact the only replacement part the Assist guys carry.

It's also the only replacement part I carry

Cause of the problem is the cooling holes in the cover allow rainwater to enter the fuel pumpt area, and it cannot escape. Result is the resistor pack sits in a puddle of water until its own heat evaporates the puddle.

Worthwhile lifting teh cover and checking the state of this from time to time ?

Maybe that's why they left the cover off the GSA so you could more easily see when it was going to fail

 

[Emoto]

Does anyone have the part number and/or know the cost of this part? Seems like it might be worth carrying one...

 

[John Armstrong]

Is it #5?

 

[Clive]

Is it #5?

Yep - less than £50 - I can't recall exactly how much it was.

 

[MikeP]

Maybe that's why they left the cover off the GSA so you could more easily see when it was going to fail

Nope it was left off in their desperate attempts to keep the weight (just) below that of the lardy 1150 Adventure!

 

[Gipsy]

As someone who has had a new pump and electrics under warranty, but whose bike's warranty expires at the w/e, I read this thread with interest. I make no claims to being a great mechanic, but will have a go at most things. Do peeps think that this job is simple enough for a well intentioned amateur to have a go at, and if the answer is yes does anyone know where I can get a set of instructions?

 

[Big Lee]

Any pics of the location & part?

 

[Magwych]

Item #5 it is, easikly accessed behind the large left hand side panel, on top of the tank. Th ecover lifts off, and the "pump" is held in place by two bolts. It took Mr Assist about two minutes to change over. Will get photos once the digital camera has recharged.

 

[Big Lee]

Cheers

 

[Magwych]

Hopefully I have uploaded the image here ...I have removed the side panel and the cover ( twist, fiddle, curse and lift). The pump resistor pack is the now shiny bit with the cooling fins on ( not the cylinder in the background !). You might notice how corroded the screw nearer the front is, and the cruddy tide mark around the pump...

 

[Big Lee]

Cheers

I`ll have a look at mine tomorrow although mine is few and far between left outside in the rain

 

[NeilG]

Maybe tempting fate but.........

No problem after two and a bit years, lots of wet miles and bike left outside under cover.

Made sure that the pump connector was doused with ACF50 and the 'vents' in the plastic cover closed with duct tape. Still plenty of ventilation but less chance of any water getting in, and if it did the chance of corrosion would be significantly reduced.

Mod approved by service guys at two dealers.

 

[minkyhead]

should bmw customers have to be doing this themselves ..this is so common its untrue ... why dont they put it right
theve been turning them out with the same fault for nearly three years ????its the fact that they know about it only to well and do absaluly nothing to put it right that annoys the most
this mod or a mod should be done at the dealers before it gets near a customer
having been a victim myself i think it sucks and continues do do so it was only a few weeks ago civil was stuck in spain on his hols with a entirely avoidable breakdown so annoying and its not even my bike and i dont even know him
http://www.ukgser.com/forums/showthread.php?t=83527

 

[Magwych]

It's only six months old!

 

[minkyhead]

It's only six months old!

luxury......................?

 

[Gipsy]

Have now had a chance to look under the cover. My new unit which was changed in June is already showing signs of corrosion. One of the bolt heads is already rusting, and the heat fins are getting furry. Wiring connections as yet appear ok however any water will run down into the connecting blocks, and may already be corroded. Rather than use WD40 or ACF50, I plan to clean it all up with a fine brush, and then seal the heads of the screws using silicon sealant. I'll also put a fine covering on the wires and down over the connecting blocks to prevent water ingress.
To judge by mine, if there is a failure after a few years the bolts could be very corroded, and hence difficult to remove in event of failure.