Really neat Fuel Pump Controller bypass

[AndyW]

How's this then?

...as an alternative to the options already detailed for example here on ukGSer: 1200GS Fuel Pump Bypass Cable

The latest generation workaround - just remove failed fuel pump controller and connect between the connector plugs on the bike, much better than having a long flylead to the battery or splicing wires into the bike's wiring and easily carried under your seat. The black connector is the original from the fuel pump controller!

Full details and instructions on dismantling a failed Fuel Pump Controller to remove the black FPC connector and making the bypass lead can be found here (blow by blow instructions with lots of photos):
BMW R1200 R1200GS Fuel Pump Controller Bypass

 

[badgerrrrrr]

looks alot netter than the fly leads

 

[Mr K]

Neatly done Andy.

 

[Fanum]

Great write up and article, and it looks very neat, but when I went into a BWM place to see if I could get a failed unit, I was told they all got sent back to be claimed for

I did manage to get a bunch of the blue connectors, but it looks like I'll have to try again to get a failed unit complete so we can carry a neat bypass

 

[Pukmeister]

Now why didn't I think of doing that when I had my old failed FPC available.

 

[Bryn]

Great write up and article, and it looks very neat, but when I went into a BWM place to see if I could get a failed unit, I was told they all got sent back to be claimed for

I did manage to get a bunch of the blue connectors, but it looks like I'll have to try again to get a failed unit complete so we can carry a neat bypass

I got mine from the dealers.. there's a certain time frame where BMW can ask for the bits back for examination.. once that's passed there should be no problem in getting one

 

[Aggy]

Extremely neat idea

Could you leave the plug in the alloy housing and connect the lead to the bottom so that you could fit the now empty housing on the the original mounts and use the original gasket so that you have a certain amount of waterproofing if you have to use this over a period of time?

 

[AndyW]

I did think of that but....but but............ok I didn't! Great idea I see no reason why not other than the small disadvantage of size.
Maybe someone can post me a photo of a version like this sometime please

I'll add your suggestion to my article Aggy, thanks.

 

[[email protected]]

would anyone

make a few of these up for sale, Im going around europe in august and Im not sure that IM savvy enough to make one up, would purchase one for a reasonable price rather than buy a new FPC from BMW

 

[Wapping]

Extremely neat idea

Could you leave the plug in the alloy housing and connect the lead to the bottom so that you could fit the now empty housing on the the original mounts and use the original gasket so that you have a certain amount of waterproofing if you have to use this over a period of time?

With all that fiddling and piddling around you might as well go and buy a proper replacement (with its free state of the art new gasket and shiny screws) from BuMW and have done with it.

But, hey, what am I thinking? This is UKGSer, why do things the easy way?

 

[Wapping]

make a few of these up for sale, Im going around europe in august and Im not sure that IM savvy enough to make one up, would purchase one for a reasonable price rather than buy a new FPC from BMW

Will you be savy enough to carry the tools to get the old cotroller out, in the dark, in the rain?

Just go and buy an off the shelf replacement as a stand-by. It is so much easier.

 

[[email protected]]

bmw

yes but so much more expensive, the more fuel money/beer money I can have the better, could just get BMW breakdown to come and get me, but Id rather not have the hassle that I had last time with my Triumph, you never breakdown near a town or phone and always where there is no mobile signal, IM rather hoping my bike wont break down, but IF i could just plug something in and get somewhere rather than taking things apart in the dark, Id be a happy biker, Ive ridden for 20 odd years, but Im SHIT MECHANIC and will always go for the easy option given the choice and this seems a lot easier to me, however I will bow to your much greater knowledge

 

[g.s.john]

o.k stupid question from an 1100 owner i aint up to speed with all this new fangled electrickicals if the bike works with a by-pass why do you need a fuel pump controller in the first place???

 

[Mr K]

o.k stupid question from an 1100 owner i aint up to speed with all this new fangled electrickicals if the bike works with a by-pass why do you need a fuel pump controller in the first place???

The by-pass makes the pump run constantly - It's a get you home thing. The FPC chooses when to pump and how much.

 

[Wapping]

IM rather hoping my bike wont break down, but IF i could just plug something in and get somewhere rather than taking things apart in the dark, Id be a happy biker, Ive ridden for 20 odd years, but Im SHIT MECHANIC and will always go for the easy option given the choice and this seems a lot easier to me, however I will bow to your much greater knowledge

You can't just plug it in You have to take bits apart (dark or otherwise) at least just as much as you have to do to replace the entire FPC (it's not very big) with a work around and it is certainly no easier.

In short.

Make sure you have suitable tools, I'm not sure if the standard kit has all the bits you will need. A torch is good if it is dark, or build a fire.

Remove left hand side panel (and a bit more on the GSA).

Locate fuel pump controller.

Remove fuel pump controller.

Undo electrical plug on top (you may need long nose pliers).

Two retaining screws (check you have a suitable bit and probably an extension in order to reach them) be careful you do not slip and round the heads or you are stuffed until you can work out how to get the buggered screw out.

Remove electrical plug underneath. Again long nose pliers may be handy.

Insert work around (or brand spanking new off the shelf FPC).

Reassamble. Those pliers will now be a Godsend.

Push starter button and cross fingers. Discover it was EWS failure after all, or the kill switch was off. Or discover - as the dawn breaks over the eastern horizon - that the work around you bought from a Tosser on UKGSer wasn't quite as well made as matey said it was.

Buy new FPC on return (so you have not saved any money) but there again, if you have one of the new black FPC's it may not fail anyway, so chin up.

PS You can do it with about three inches of bog standard twin core bell wire or lamp flex, if you want the full hedgehog in pocket experience. I remain indebted to St Eptoe for that wonderful expression.

 

[g.s.john]

The by-pass makes the pump run constantly - It's a get you home thing. The FPC chooses when to pump and how much.

thanks

 

[Wapping]

The by-pass makes the pump run constantly - It's a get you home thing. The FPC chooses when to pump and how much.

... and if you wire it direct to the battery the pump will continue to run until:

(a) The battery goes flat. Blame BuMW as they all do.

(b) You disconect from battery. Using the inline fuse as a switch is a simple method.

(c) The pump burns out. OK I have never heard of one doing it but there is always a first....



You can though use it as a pump to empty diesel out of the tank. But that's a different story.

 

[woodman]

slight simplification

This is brilliant. My (2004 GS1200) fuel pump controller failed at the weekend. I followed these instructions and the bike was running in 1 1/2 hours. Here is a slight mod to the method. Once the circuit board is reveled, carefully prise it out. This pulls the 3 pins through the base of its housing. cut the circuit board round the pins with side cutters. Remove the housing as described, push the pins back through their holes and you are ready to solder the leads on.

Thanks for this

 

[nix]

Looks great to me as a get you home solution.

Out of curiosity how much is a new FPC ?. My engine has stopped twice unexpectly and although my dealer couldn't find a fault , I can't help feelling it;s just a matter of time.

Nick

 

[Bots]

Hello,

Very good idea!

But, who can help me, which wire (yellow & blue) do you connect to which (3 pins)?

Thanks.