R1200GS Fuel Pump Failure

[Clive]

BTW should there be a torx key in the toolkit that fits the fuel pump controller. I couldn't remove mine because the smallest key in the toolkit was too big.

There was an ominous space in the toolroll though!!

Just so happens that I have mine next to me - have been tracking down a set of "socket versions" that I can use with a Torque wrench - you should have 5 torx keys - the smallest is T25

 

[Wraithwrider]

I'm fairly sure that mine has 4 (will check Friday). Not sure what size my smallest is or what size the fuel pump controller bolts are either.

Maybe I need to to contact my supplying dealer?

 

[Clive]

I'm fairly sure that mine has 4 (will check Friday). Not sure what size my smallest is or what size the fuel pump controller bolts are either.

Just checked mine after being prompted by this thread. You need a T20 torx key.

I had a small amount of water in there - no rain recently so must have been from the wash I gave the bike at the weekend. I didn't find any water inside the controller cavity - no sign of corrosion anywhere except around the outside (exposed) edge of the controller - that looks a bit like limescale. Used a smear of vaseline around the blue o-ring when I put it back together.

 

[GSmonkey]

I'm thinking of running a bead of silicone around the damn thing when it gets fixed.

 

[ed4554]

Checked mine today. Egg cup of water in top recess. No water under controler. However the "o" ring on mine was black not blue as others have posted. My bike was August 04 build. Could BM have updated the "o" ring at some time to stop water getting where it should not?

Ed

Ride Safe All

 

[Dutchman]

Service Information #08/2005

Here's the latest :

Situation:

Water ingress past the blue O-ring into the cavity underneath the fuel pump electronics. This can cause sporadic failure of the fuel pump unit.
Hazardous situations could result if the engine were to cut out unexpectedly and possibly start firing again just as suddenly.

Series Solution
As a provisional measure adopted in series production since July 29, 2004, a black O-ring seal that is 2mm shorter around has been installed: this O-ring solves the problem and does not have to be replaced.
As of VINs ZR20403 (ECE) and ZL78234 (US), motorcycles leaving the factory have new turquoise-coloured profiled seals that definitively solve the problem

Models affected
R1200 GS ((ECE)europe) VINs from ZL25000 to ZL29999 and ZN25000 to ZN31286

R1200 GS (US) VINs from ZL75000 to ZL76160

If your's falls within these VINs you should receive a recall notice from your main dealer for a replacement seal to be fitted. If you do not receive anything contact them and quote the above service information number.

 

[FortyZA]

Hi Guys,

I have had the same fault on my 2005 R1200GS, brand new bike, still not registered. BMW here in RSA say they are not aware of this problem. Now my bike is running after they repaired the pump, but now the engine light is on and it is in it's second week with me. It must go in for it's 1000Km service. I look forward to any further comments.. I wonder if the problem is not quite solved, and causing the engine light to come on??

 

[Paul Wakefield]

Eddie,

You could be right. My engine light came on when it started to fail a few months back. Also it is not the pump itself that packs up but the electrical thingummyjigs -so hopefully your dealer replaced those.

Paul

 

[JayGee]

Re: Service Information #08/2005

Here's the latest :

Situation:

Water ingress past the blue O-ring into the cavity underneath the fuel pump electronics. Models affected
R1200 GS ((ECE)europe) VINs from ZL25000 to ZL29999 and ZN25000 to ZN31286

R1200 GS (US) VINs from ZL75000 to ZL76160

.

Thanks for the info., not sure how you came by it but if genuine it's interesting cos mine is amongst the VINs affected yet I have had no recall or anything from my dealer.
Have any other members had a recall?
Cheers JG

 

[Dave Price]

My dealer (Clarks of Rednal), mentioned that they were aware of a problem at the first service in June last year, and would take care of it. I assume that most of the dealers may have taken this approach.
I've certainly ridden in some heavy rain since, and without problems.

 

[Mrs C]

I'm not 100% sure of the schedule as far as issuing recall notices goes but the parts are currently enroute to Park Lane and I should imagine, most other dealers by now as a technical bulletin has been posted reference the defective seal on some bikes.

If you don't hear anything it's always worth checking with your local dealer if you're in any doubt as it may be a case of notifying owners of affected bikes in phases over a period of weeks.

 

[Dutchman]

Re: Re: Service Information #08/2005

Thanks for the info., not sure how you came by it but if genuine it's interesting cos mine is amongst the VINs affected yet I have had no recall or anything from my dealer.
Have any other members had a recall?
Cheers JG

Of course it's fekkin' genuine.........why would anyone post a load of bollox..........

Oh........I've answered my own question there..........

I have the actual Campaign Notice here, but it's too much to post.....so I thought the text & reference number would suffice.....it's dated 4th February, so perhaps individual dealers (like my own) are slow to react.........?

Cheers

Dutch

 

[JayGee]

Re: Re: Re: Service Information #08/2005

Of course it's fekkin' genuine.........why would anyone post a load of bollox..........
...
Cheers

Dutch

OK Dutch, I wasn't implying you were peeing about but I'm not so sure about BMW management and their dealers.
I'd like to think the mod was done either prior to delivery in July 04 or at the first service in August 04 but I doubt it.
I've had a lot of crap info from other bike forums but I must say that I've only had genuine, useful info on here, the trouble is the dealers don't seem so well informed. For example after hearing about a new s/w update last year I asked the dealer to update my bike to try and cure the surge at 2,500RPM and whilst they did eventually find a new CD they didn't seem to know much about it.
So, sorry if my post offended, it was certainly not intended that way, and thanks for the detailed info.
Cheers JG

 

[Dutchman]

Re: Re: Re: Re: Service Information #08/2005

OK Dutch, I wasn't implying you were peeing about but I'm not so sure about BMW management and their dealers.
I'd like to think the mod was done either prior to delivery in July 04 or at the first service in August 04 but I doubt it.
I've had a lot of crap info from other bike forums but I must say that I've only had genuine, useful info on here, the trouble is the dealers don't seem so well informed. For example after hearing about a new s/w update last year I asked the dealer to update my bike to try and cure the surge at 2,500RPM and whilst they did eventually find a new CD they didn't seem to know much about it.
So, sorry if my post offended, it was certainly not intended that way, and thanks for the detailed info.
Cheers JG

No problem.......

......it's no surprise that the dealers aren't up to speed.......I don't think they bother even reading the bulletins, let alone acting on them.......

I doubt that your dealer would be aware of the problem back last year, unless they had personal experience.....

I had TWO breakdowns in two days last year in NL & Germany as a direct result of this failure.

The first dealer just dried out the connectors & got the bike going, the second, in Germany had experienced the problem several times so had a stock of the 'O' rings & fuel pump controllers, not as a result of a recall, just personal experience.......

I'd suggest you hassle the dealer until he does the job for you.......heavy rain is enough to flood the area concerned......

Cheers

Dutch

 

[JayGee]

Re: Re: Re: Re: Re: Service Information #08/2005

No problem.......

...

I'd suggest you hassle the dealer until he does the job for you.......heavy rain is enough to flood the area concerned......

Cheers

Dutch

I'll be going in at the weekend, armed with your info!
I seem to have only ridden it in heavy rain, but maybe I was just lucky.
Cheers JG

 

[Deleted Member MM]

Re: Service Information #08/2005

Here's the latest :

Series Solution
As a provisional measure adopted in series production since July 29, 2004, a black O-ring seal that is 2mm shorter around has been installed: this O-ring solves the problem and does not have to be replaced.
Models affected
R1200 GS ((ECE)europe) VINs from ZL25000 to ZL29999 and ZN25000 to ZN31286
If your's falls within these VINs you should receive a recall notice from your main dealer for a replacement seal to be fitted. If you do not receive anything contact them and quote the above service information number.

Both our 12's fall within affected VIN no's (Told mine was Aug build? ) No recall rec'd.. trip to Dealer on Sat then.

 

[JayGee]

Recall recieved today

Received letter in post today from Pidcocks asking me to book-in for rectification. No mention of what exactly the problem is but I assume its the fuel pump/controller.
So, at least Pidcocks are doing their best to rectify this problem and maybe I under estimated BMW and the dealers ability to organise a piss-up in a brewery (or in this case a break down in a piss-down)

 

[FortyZA]

Seems to me BMW have withheld info in order to try and solve the problem but under estimated the power of the Internet. BMW here have issued the same service notice and bikes are being checked when coming in for a service. Thanks for the help and advice. You guys will be hearing from me again soon.

Regards
Eddie

 

[Dutchman]

The big question is, of course, is that BMW AG were obviously aware of the problem way back last summer, if they were altering production spec from 29th July....

....why, therefore did it take them nearly seven months to issue the recall here in the UK?

Was the recall in existence in NL & Germany when I had my two breakdowns last October?

This is a potentially dangerous fault (as experienced by me personally) as the symptoms are akin to running out of pertol.....

.....imagine committing to an overtake, being alongside the target vehicle & then cough, splutter....no fekkin' power..........

My correspondence with BMW on this subject continues........

Cheers

Dutch

 

[Paul Wakefield]

then cough, splutter....no fekkin' power..........

Which was exactly the symptom that happened to me during an overtake though it was fortunately just reduced power rather than complete loss.

Paul