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

Just had mine go. Bike is a registered Sept 2008 - only done 2000 miles. Ride in most weather. Let me down in city traffic 40 miles from home. BMW recovery dropped bike at dealer and then took me home. Got bike back after 2 days. I'M NOT HAPPY:mad::mad::mad:
 
Changes to FP relay design

2007 1200GS model
6000miles
Intermittant fault for 2 weeks then would not start @ home (luckly bank holiday weather crap as usual!)
Recovered to local dealer and collected next working day.
New FP relay fitted AND A VENTED PLASTIC COVER OVER THE ENTIRE MODULE AREA (to prevent water ingress), anybody else had this fitted?(dealer had all parts in stock & was aware of this thread!).
No lost days just late for one meeting!
 
Mine went 04/04/2009

1200 GSA October 2006 17,000 miles.

fixed by Riders Cardiff under warranty (extended)
 
I've also had a FPC failure.

When: march 2009
Where: jerusalem, israel
Name: roei
Bike: 2007 R1200GS - 54k Km
Remedy: BMW local dealer fixed it under warranty.
Cost: -

Tim said:
Thanks for the report. I won't add it into the UK figures but it's good to know the UK isn't alone in this problem.
 
fuel pump module failure

I have just had breakdown on saturday.
When-Saturday 18/04/09
Where-My driveway,Hamilton
07 GS1200 3800miles
Repaired by BMWassist mechanic.Phoned 12:50,bike running again by 18:00.
BMW mechanic said common fault caused by module lying in water in recess in top of tank.Plastic cover has slotted holes in it to cool module so is no good at keeping water at bay.We greased round new module with waterproof grease but will need to keep an eye on this after washing the bike as collecting water seems to be the problem here.
 
where...north wales.when.....last week.who....wideparting.bike 06.gs1200. bike recovered home by rac.£67 for a new one.
 
FPC

FPC Failure

When: 26 Apr 09
Where: Home
Milage:13k
Model: GSA
Year: 07
Name: Barry G
Recoverd: BMW Assist
Returned: BMW Assist
Time:3 Days
Cost: Nil (still under warranty)

Hi Tim, Hope all's well in your world.

Barry G
 
2008: 125
2009: 13

Total: 246

The route I am now following is submitting Safety Defect Reports to VOSA, the government vehicle safety agency. If you have experienced a fuel pump controller, please download the form from here (right click and 'save target as') and email the completed form to me at tim dot cullis at infar dot co dot uk.

Cheers
Tim

Hi Tim
I have sent a copy of the vehicle defect form directly to the VSA and have had a response from them. Have you done anything along these lines yet?

Cheers
OldCroc
 
Yes, I've forwarded on a dozen or more reports. It's about time to rattle the cage again and ask for an update.

Hi Barry, sorry it eventually went.

In the meantime,

When: 25 Apr 09
Where: middle of nowhere
Milage:9k
Model: F800S
Year: 06
Name: John Uytman
Recovered: rescue services
Cost: £85
 
Well, thought I'd escaped this ... but it wasn't to be ...

Model: R1200GS Adv
Year: 2006 (initial launch fleet)
Milage: 33.5k

When: last night! (30th April 2009)
Where: 100+ miles from home
Name: Craig Morgan

Recovered: AA (relayed to home)
Cost: N/A

Bike stumbled and died (fuel starvation) on one of the worst rat-run roads on the route (B3011). Luckily it restarted once and I managed to get within 100yds of a safe-haven. Called AA, who turned out expecting a "tank run dry", when they got there I'd already stripped the bodywork, etc away and suspected the FP controller module. Mine was nicely sealed up and still shows signs of insulation grease on the upper connections, but, the lower torx screw and FP are well rusted and crud encrusted.

We tested and proved to our satisfaction it was the module ... bike recovered to home, will order parts this morning (its out of warranty).

I'd watched others around me get bitten by this, checked, cleaned and sealed mine in the past and I suppose I was lucky it eventually went when in the UK ...

Craig

Ps. Tim, VOSA doc on the way in email ...
 
Last edited:
So things are starting to hot up again. I'll be really interested to see if we get any 2008/09 models going wrong, and whether the overall failures come anywhere near last year's. Or perhaps the latest iteration of the FPC really was the fix?

Update on failure statistics (UK owners only)

2004: 7
2005: 16
2006: 31
2007: 56
2008: 126
2009: 33

Total: 269

The route I am now following is submitting Safety Defect Reports to VOSA, the government vehicle safety agency. If you have experienced a fuel pump controller, please download the form from here (right click and 'save target as') and email the completed form to me at tim dot cullis at infar dot co dot uk.

Cheers
Tim
 
When: May 2009
Where: Stourbridge, UK
Name: Deeley
Bike: 06 GSA
Remedy: :mad:
Days lost: another day immobile
Mileage: 11400

Third time of this issue.
 
Another FPC failure

I am now a fully fledged member of the Knackered FPC Society! I've had my 1200GS for 3 years and covered 21500 miles (the first 1500 were done by the previous owner). In that time I have enjoyed fault free riding across Europe and Morocco. But last weekend my FPC gave up. Fortunately I had only gone 2 miles from home when it went pop. Unfortunately, the pub it happened outside was closed and I had to push the damned thing home.

The failure was caused by something burning out in the unit - I removed the rubber sealant and found a big black burnt out patch (I took a photo, but at the moment can't be bothered to download it!).

I was going to take the bike to Chester Motorrad, but the symptoms seemed to fit with other descriptions on here - riding along as normal when the engine just cut out and wouldn't restart. So I ordered a replacement FPC and fitted it within 5 minutes and hey presto! The old unit wasn't sitting in water although there was some dirt in the recess suggesting that water had got in previously.

I'm now going to buy a spare FPC to stick in the top box just in case the replacement gives up the ghost. I've also got a spare ring antenna just in case. My faith in the BMW brand has taken a serious denting, but hopefully that'll be the end of this little episode.

So here's the details:

When: Saturday 2nd May 2009
Where: Outside the Bull at Shocklach, Malpas, Cheshire
Name: Paul Jennings
Bike: R1200GS (2004) - 22500 miles on the clock
Remedy: new FPC fitted by yours truly
Days lost: 9 days
Incidentals: New FPC cost £67.54 plus £8 P&P from Chester Motorrad (unit was on the shelf).

Tim - thanks for taking the time to collate this data. I hope it is all worth it in the end. And thanks for your Morocco threads - they certainly made my trip last October easier. :bow

Cheers,
Jenkins.
 
Given all these problems.......... what can be done to prevent it? - other than not buying an R1200 GS/A!
I am seriously considering a 1200GSA but becoming wary after reading some of the problems being reported.
:eek

I am hopeful that the latest version has fixed things, however until BMW comes clean on the situation we don't really know. Perhaps a letter to your dealer copied to BMW Customer Services telling them your buying decision is on hold might help. I know it's only one instance of £12000 or so, but you are not the only person in that position.

Tim
 
When : yesterday
Where: does it matter?
Rider: Chartswood
Model : Jan 07gsa 23400 mls
Remedy: fitted the spare I carry 25mins tops.
No water ingress visible at all under fpc or around fittings.
Mate on his Norton Commando pissed himself laughing!
 
I am hopeful that the latest version has fixed things, Tim

Tim, I wouldn't be too sure that the latest version has fixed anything as I have recently had this response from a BumW dealer:
"BMW have advised me that they are working with the Factory (Munich) and VOSA to apply a permanent ‘fix’ solution to this problem. They will not give any undertaking to the time scale.........."

This was in response to my complaint after my bike failed with 2000 miles on the clock and me sending a form to VOSA. :nenau

OldCroc
 
My next bike will be japanese

When : 2009-05-12
Where: Oslo, Norway
Rider: Me
Model : 2005 R1200GS
Remedy: Haul to garage. Replaced controller AND puml (!)

My next bike will be japanese.

Tim said:
Thanks for posting, I won't include your incident in the UK figures, but it helps to show this is a worldwide problem.
 
Interested to note VOSA involvement. Downloaded Tim's link to VOSA, completed form and sent to both Tim & VOSA. Delighted to report that VOSA have respond via letter so would highly recommend this course of action, well done Tim!

As a side note maybe switching 57 for 09 model, is it worth it?
 


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