The sorry saga of 1200GS/GSA fuel pump controller failures (410 so far)

[robvanelst]

Mine failed yesterday evening, 2006 R1200 RT (not a GS but close enough ). I carried a multi-meter and noticed I couldn't measure any current on the plug coming from the module. More oddly, it wasn't the "plus" that was missing, it was actually the earth that seemed disconnected. I ended up wiring the pump's earth straight from the battery and that got me home. Looking at this thread, I don't think I will bother replacing the module but clear up the fix and make it permanent.

Mind - I am a returning BMW owner for 3 weeks: I owned Beemers from 1985 - 2001, then 4 gearbox failures, countless oiled up clutches and an exploded (!) end-drive housing made me go Japanese; as much as I enjoy the RT's ride, I am still to be convinced that BMW makes bikes fit for daily use...

 

[Meath]

Think I might be added to the list. Usual symptons the other day. full tank of petrol, starter turned as normal but engine doesn't fire.
But one thing, the day before it went the bike started, But it took about 3 presses of the starter button. Bike always starts first press of the button, so thought it was unusual. But it eventually started and it cut out after about 20 seconds. But started again. Next day it wouldn't start at all.
Does that sound like fuel pump controller?

 

[Pukmeister]

Think I might be added to the list. Usual symptons the other day. full tank of petrol, starter turned as normal but engine doesn't fire.
But one thing, the day before it went the bike started, But it took about 3 presses of the starter button. Bike always starts first press of the button, so thought it was unusual. But it eventually started and it cut out after about 20 seconds. But started again. Next day it wouldn't start at all.
Does that sound like fuel pump controller?

Yes, identical symptoms to mine when it packed up.

 

[Pukmeister]

Make a "get you home" lead from the failed units connector for the future. Carry a small cheap security Torx tool with it and then you can fix it again or help other stranded riders if you come across one.

I recall Wapping did a thread called something like FPC bypass cable, it's all on there.

 

[robvanelst]

Make a "get you home" lead from the failed units connector for the future. Carry a small cheap security Torx tool with it and then you can fix it again or help other stranded riders if you come across one.

I recall Wapping did a thread called something like FPC bypass cable, it's all on there.

I don't know if the module always fails in the same way but I have the pump's earth permanently wired to the battery. I think I will buy a new module but carry it rather than fit until the old module deteriorates even further. On my Buell, I never leave the house carrying spare starter relays and engine mount bolts with me. Ah, the virtues of owning brilliantly designed- but shockingly poorly implemented motorcycles

I wonder how many modules, clutches, gear-boxes and drives Ewan McGregor and Charley Boorman have burnt through on their adventure(re)s - in many ways our beloved bikes seem very solid and over-engineered, but unfortunately not consistently enough to end up with a mostly worry-free motorcycle. It's great that modern BMWs are priced much more competitively than, say, 30 years ago, but personally I wouldn't mind paying a few grand more for something that didn't need so many repairs, anti-corrosion treatments and causing concerns for taking on long trips.

 

[Meath]

Might as well fill out the template

- When did it happen? Around 20-06-2013
- Where were you? At home thank feck
- rider name? Meat
- bike details (model and year) 2006 1200 GSA
- remedy - Bought part and fitted it myself.
- How many days work/holiday did you lose? Zero, lucky I just bought a car a week earlier, so had transport. Usually use the bike for everything.
- Were there any incidental costs? No

Also worth noting, when I took a look at my old one, it was covered in grease. Wiped it all off to get in at the 2 screws. But there was only one holding it in. When I took the old one off, the little chamber inderneath was half full of water and half full of the same grease. My guess is that a lazy bmw mechanic was doing something there before, lost a screw and just used blobs of grease as a sealer.
Here's a photo of the dodgy part.

 

[AndyW]

James has sent the following message from the Contact Us page on http://www.motorcycleinfo.co.uk/:

"Hi Andy
I suffered from this earlier this week on my 2004 GS and just now made the old unit into a bypass. By careful use of my soldering iron I got the circuit board out in one piece, and found that the surface mount resistor just north of the 8-pin chip had become detached and there were signs of heat damage around it. I have measured the resistance of the part and it is, for the record, 220 ohms. I wonder if anyone else has noticed the precise area of fault; if it is common, then a generic repair might be developed and publicised. I'll keep you posted if I succeed."

 

[DrFarkoff]

James has sent the following message from the Contact Us page on http://www.motorcycleinfo.co.uk/:

Andy your link had extra characters

http://www.motorcycleinfo.co.uk/

 

[Nick V]

Might as well fill out the template

- When did it happen? Around 20-06-2013
- Where were you? At home thank feck
- rider name? Meat
- bike details (model and year) 2006 1200 GSA
- remedy - Bought part and fitted it myself.
- How many days work/holiday did you lose? Zero, lucky I just bought a car a week earlier, so had transport. Usually use the bike for everything.
- Were there any incidental costs? No

Also worth noting, when I took a look at my old one, it was covered in grease. Wiped it all off to get in at the 2 screws. But there was only one holding it in. When I took the old one off, the little chamber inderneath was half full of water and half full of the same grease. My guess is that a lazy bmw mechanic was doing something there before, lost a screw and just used blobs of grease as a sealer.
Here's a photo of the dodgy part.

I have a functional, early-model pressure controller open and on my desk at the moment.

Taking a look at this photo, it looks like at least three, and possibly four, resistors are heat-damaged.

Has anyone else on the site also taken their dead FPC apart in this manner, and taken piccies? Is it the same components which fail in every case, or is there variance between failed components?
If piccies have been taken, please could their owners do me the kindness of forwarding them?...

If so, it would be extremely useful to see them for the next article I'd like to write (Permanent repair of a failed FPC).
I would pull more FPCs apart, myself, but the weird thing is, I have never had a failed FPC on any of the BMWs I've owned (2x F-series, 1x K-series, 3x R-series).

 

[Sandman]

Dead fpc:

- When did it happen? Tuesday 4th Feb 2014
- Where were you? Lane 3 of the M6, northbound at J17.
- rider name - Sandman
- bike details (model and year) - R1200GS, 2006, 15800m
- remedy - Bike recovered to home address and fpc replaced with brand new item (£30 of ebay!!!)
- How many days work/holiday did you lose? None
- Were there any incidental costs? The price of a "monster" can of Monster to the recovery driver.

 

[AndyW]

Andy your link had extra characters

http://www.motorcycleinfo.co.uk/

Thanks, result of copy and paste without brain engaged! lol

Another one for the stats.......

"Hi Andy
I just want to thank you for putting stuff and information on this page. The instructions on how to bypass the fuel pump controller helped me to get my R1200GS going again. After a splash of rain it suddenly stopped on my way home from work. Although it has to be said my motorcycle already did 189'600 km (117'812 mi) and it never let me down before.
Keep up the good work!
Greetings from Switzerland
Damian Waldmeier"

 

[MrFell]

Mine started to pack up a couple of days ago.

55 plate with 50500 miles.
Normally starts first time every time, then came the hesitant starts.
Booked into BMW Clarks for service today and FPC unit check.
Just had confirmation from them it is the control unit that has packed up. Apparently its about £106 to the part.

I have also got a check on another part of the fuel pump which is a BMW recall. Not exactly sure what thats for yet though....

 

[cammy5477]

I have a 2009 GSA. I have read through many of these posts from people with issues but I haven't seen to many that I recall on the 2009 and above models

Is this the case or am I on possible borrowed time?

 

[Deleted account 190920001]

I have a 2009 GSA. I have read through many of these posts from people with issues but I haven't seen to many that I recall on the 2009 and above models

Is this the case or am I on possible borrowed time?

The 09 bikes (possibly all MK2 bikes 08 on) had a redesigned unit plus a different shaped tank so the controller doesn't sit in a pool of water. Theory being you shouldn't have a problem.

 

[cammy5477]

The 09 bikes (possibly all MK2 bikes 08 on) had a redesigned unit plus a different shaped tank so the controller doesn't sit in a pool of water. Theory being you shouldn't have a problem.

Thank you for being the bearer of good news for a change mark

 

[cookie]

Thank you for being the bearer of good news for a change mark

sorry to be the bearer of bad news

...but it was only the GS that got the redesigned tank. i note you have a GSA which has the same tank as previous models (and the later TC) which does allow the FPC to sit in a pool of water.

on a brighter note, if you have one of the later black FPCs, properly fitted, with a greased seal so it doesn't leak water down to the connector below, it is very unlikely to fail anyway

 

[Deleted account 190920001]

sorry to be the bearer of bad news

...but it was only the GS that got the redesigned tank. i note you have a GSA which has the same tank as previous models (and the later TC) which does allow the FPC to sit in a pool of water.

on a brighter note, if you have one of the later black FPCs, properly fitted, with a greased seal so it doesn't leak water down to the connector below, it is very unlikely to fail anyway

No it isn't, the 09 GSA has a different tank or was always designed properly. The FPC sits on a slope so it can't sit in a puddle. Either that or my 09 must be very special which I doubt.

 

[cammy5477]

Good news then bad news then good news
Which is it guys

 

[cookie]

No it isn't, the 09 GSA has a different tank or was always designed properly. The FPC sits on a slope so it can't sit in a puddle. Either that or my 09 must be very special which I doubt.

ok, i admit i have never actually seen an 09 GSA tank with the covers off, but i always understood that only the GS ever got the relocated FPC. furthermore, i do have a 2011 GSA which has the FPC in exactly the same place as my old 06 GSA, so unless BMW changed it for the 08/09 bikes* and then went back again, it's in the same place it's always been.

*here's a clue - they didn't. pic is of an 08 which is the R1200GSA MU/facelift model same as an 09.

 

[AberdeenAngus]

I've got an 09 GSA and the lower corner of the FPC can sit in a puddle.
From what I understand, the black finned units are a great improvement on the earlier silver finned ones.