Unreliable but predictable fuel pump controller failure

[Bungy]

Frustratingly I broke down this evening with the symptoms of running out of fuel. One benefit of having a smart phone was the internet search while I waited for recovery which was excellent and organised by Carol Nash. A bike specific van arrived and took me home. 20 mins later and I had the FPC bypassed and the bike running. There was a small amount of water under the controller when I removed it. My short ownership of this GS has been a love/hate affair but positive enough to buy another which I collect on Thursday. I just wish the FPC could have waited a few more days. I will be carrying a spare bypass lead in with my under seat tools for sure in the future.

 

[Bendy toy]

Reminder to me - take out FPC and grease underneath to keep water out.

A length of 6mm clear hose warmed and shaped into a curve at the end can syphon water out of the fuel tank cover plate. Feed some candle wick string inside the tube to wick the water away. Many cars have a rubber boot over the fuel tank access covers. It's worth investigating if any are suitable for the bike and if they'd help or aggravate the the water problems.

 

[autogs]

you really do talk a load of bollocks

 

[cookie]

just make sure the seal is good and fitted properly.

 

[Sgt Bilco]

You were unlucky mate and that must have been the very last original FPC.

 

[DrFarkoff]

Mine is an original first generation pump controller (it was a new unit in 2005 replaced when original failed on my pal)

My cure leading to my units extended lifetime?? Simples just bend and fit a bit of plastic coke bottle or oil can plastic into a lid for the controller vented cover to stop any water getting in but leaving a side open to draw hot air out of the pump top area

 

[Bungy]

You were unlucky mate and that must have been the very last original FPC.

Is this a problem that has gone away with later models?

 

[Sgt Bilco]

Is this a problem that has gone away with later models?

Yes mate, the FPC was a bit of a nightmare on early bikes but should all have been changed under warranty for uprated controllers. I've not heard of any problems on post 07 bikes.

 

[Bungy]

Yes mate, the FPC was a bit of a nightmare on early bikes but should all have been changed under warranty for uprated controllers. I've not heard of any problems on post 07 bikes.

That is good news.

 

[Bendy toy]

Mine is an original first generation pump controller (it was a new unit in 2005 replaced when original failed on my pal)

My cure leading to my units extended lifetime?? Simples just bend and fit a bit of plastic coke bottle or oil can plastic into a lid for the controller vented cover to stop any water getting in but leaving a side open to draw hot air out of the pump top area

Do have pictures to illustrate this?

 

[Bendy toy]

you really do talk a load of bollocks

Of course I can't find proof on eBay but cover boots certainly existed on some Alfa Romeo 156 .

 

[kevmean]

Yes mate, the FPC was a bit of a nightmare on early bikes but should all have been changed under warranty for uprated controllers. I've not heard of any problems on post 07 bikes.

My 08 gsa one failed last year and I had to pay for the replacement as BMW said it was never part of a recall.

 

[DrFarkoff]

Do have pictures to illustrate this?

No but I will go take a couple tomorrow ...

 

[Mr K]

You were unlucky mate and that must have been the very last original FPC.

Not so amigo: I'm on FPC number 3 and carry a spare - I regard them as a consumable, as they tend to fail every 3 - 4 years.

2004 model. Took great delight in fitting the last replacement outside the BMW dealer in Bath.

 

[Bungy]

I'll keep the bypass that I've made then.

 

[DrFarkoff]

I'll keep the bypass that I've made then.

Just make a rain cover my bike is a 2004 one that has had one replacement FPC in 2005 my friend who owned the bike before me broke down in Scotland

When he came to me I had a look and decided that a rain cover would keep water out and if careful I could leave the lower vents open but covered to allow some airflow

This is my bike yesterday evening I think that the STD III crew will agree it rained DAMN hard on Saturday night / Sunday Morning

My FPC area is totally dry my 1200 lives outside

What you see in the photos is a smear of waxoyl that I put in there 6 or 7 years ago ....

 

[Bendy toy]

Thread resurrection (sorry -ish).

I recently swapped my old, but working, silver FPC for a spangly new black one. Can't be too careful.

Recently the bike has been running out of fuel with 10 litres still in the tank. Time to break out the bypass wire methinks.

 

[Stuttgartmetal]

My 2010 has just pulled up like it run out of fuel
Could it be this .
How do you bypass it to check it .
TIA

 

[Bendy toy]

It might not be the controller.

A weak fuel pump will not flow enough fuel to lift petrol from the right side of the tank. It uses a venturi pump on the return flow. Mine behaved ok until I removed the broken fuel strip.

I can't find out for sure but it looks like the controller runs the pump harder when fuel level is low. This makes sure fuel is lifted without hammering the pump when tank is full. My strip has been indicating empty for months with no fuel flow issues. As soon as I removed the strip the bike ran out of fuel with 8 litres in the tank.

If true it looks like I have a weak fuel pump that's been hidden (or caused by) the controller running it harder all of the time.

Spoofing the fuel gauge with resistors - to read full and remove the warming triangle - could cause the pump to run dry with fuel in the tank unless the pump is 100%.

Nobody seems to know if the above is all entirely true but. I'm planning to test mine with an without a bypass wire and plan on getting a new fuel pump so we should find out eventually.

 

[Stuttgartmetal]

How common is fuel pump failure ?