Fuel Pump Driver Failed on an 08 R1200GS

Tantalum Kid · 08-19-2009, 08:08 PM

250 km into a weekend trip my bike wouldn't run. It would start, rev-out or idle for about 2 seconds, but wouldn't run. This happenned for about 30 starting attempts. After that all it would do is crank over, but not start. There were no warning or fault codes on the dash. BTW it was raining off-and-on all day.

Thanks to BMW roadside assistance the bike was trucked to a dealer (about a 200 km tow). The dealer diagnosed the situation as a faulty fuel pump electronic controller - aka fuel pump driver - and a replacement is currently on order (2 week delivery).

A little research revealed these controllers became wet due to a flawed o-ring seal. However, this situation was reported in 2005 and one might assume that this had been fixed for the 08 models.

1. Can anyone report this happenning to other 08-R1200GSs?
2. Is it possible to carry out a road-side replacement of the fuel pump electronic controller?

Jim
___________________
'08 R1200GS
'08 F650GS (twin)

marchyman · 08-19-2009, 08:24 PM

In the US it's a recent recall, number 09V319000 affecting '06-'08 R1200 GS.

leafman60 · 08-19-2009, 08:24 PM

Welcome to BMW ! Lol, my 07 had the upgraded o-ring and yet it leaked water, shorted out and stranded me on the freeway in Louisiana one hot summer day in rush-hour traffic.

Be warned that even the "fix" from the factory may not work. Another thread outlines the procedure for by-passing a failed controller and direct wiring the pump like on the 1150 series. That by-pass may save a lot of pain and heartache the next time it lets you down.

JR356 · 08-20-2009, 01:03 PM

Get this bypass cable from a fellow forum member,in case you have future issues:

http://www.burnsmoto.com/bmw-fuel-pump-bypass-cable.php

JetSpeed · 08-20-2009, 01:31 PM

If your dealer will give you the failed part you can make an emergency bypass with it very easily and then stick it in your under-seat tray, that's what I've done after being turned into a pedestrian twice.

BTW, once you have a bypass under your seat (and know how to use it) it will never fail again.

Wallowa · 08-20-2009, 01:40 PM

Hey has anybody actually talked to BMW NA or BMW Motorrad about how the replacement controllers will stop the water damage generated failures of the controllers?

I read the letter from Jan Urbahn from BMW NA to NHTSA. Check out his title: General Manager; Safety Enginering and Intelligent Transportation Systems! The letter is weak and doesn't specify how the controller will be modified to preclude these failures.

I mean WTF....this is another absurd issue that should not be an issue.

Delawarerider · 08-20-2009, 02:02 PM

Mine failed last week. Dealer called today and its fixed. I love the fact that my '07 GS is being repaired, but why the hell does it keep breaking down. Fork seals, key antenna ring, rear main engine seal, two final drive seals and now this fuel pump problem. What will fail next?

JetSpeed · 08-20-2009, 02:30 PM

To be honest I don't believe that the fuel controller failures are due to water or corrosion, I think that the part fails due to overheating.

bemiiten · 08-20-2009, 02:43 PM

Quote:

Originally Posted by JetSpeed

To be honest I don't believe that the fuel controller failures are due to water or corrosion, I think that the part fails due to overheating.

You are probably right. I guess I should be filling the flange with water to keep it cool!

Tantalum Kid · 08-20-2009, 04:41 PM

"Get this bypass cable from a fellow forum member,in case you have future issues:
http://www.burnsmoto.com/bmw-fuel-pump-bypass-cable.php"

Thanks for the info on the bypass cable, and thanks to all that replied. It's nice to know that I'm not alone. Also, this may explain the long delivery for the replacement fuel pump controller, i.e. high demand.

The image of the failed controller shown on the page with bypass cable seams to have a lot of electronics inside. How complicated is this device? Especially if can be bypassed by a connection to the battery. Looks like its more than just a relay.

Jim

marchyman · 08-20-2009, 04:58 PM

Quote:

Originally Posted by Tantalum Kid

The image of the failed controller shown on the page with bypass cable seams to have a lot of electronics inside. How complicated is this device? Especially if can be bypassed by a connection to the battery. Looks like its more than just a relay.

Jim

It's reported job is to reduce power (voltage?) to the fuel pump as full power is not needed once the fuel system is pressurized. The reported reason for doing this is to lessen wear and tear on the fuel filter that is an integral part of the fuel pump. Other models have an external, replaceable fuel filter and do not use the controller. When you bypass the controller with the cable you are running full power all the time.

I'm just parroting things I've read... I really don't have a clue as to how much of that is factual.

OK, I really don't have a clue.

jpooch00 · 08-20-2009, 05:06 PM

Quote:

Originally Posted by marchyman

It's reported job is to reduce power (voltage?) to the fuel pump as full power is not needed once the fuel system is pressurized. The reported reason for doing this is to lessen wear and tear on the fuel filter that is an integral part of the fuel pump. Other models have an external, replaceable fuel filter and do not use the controller. When you bypass the controller with the cable you are running full power all the time.

I'm just parroting things I've read... I really don't have a clue as to how much of that is factual.

OK, I really don't have a clue.

I think it's just OVER-doing what it was intended to do. If it shuts down the fuel pump altogether, it'll NEVER wear out - thus it'll have an infinite life expectancy!!!

Delawarerider · 08-20-2009, 07:45 PM

Yeah and if you never start the bike, it'll last forever too. But WTF good is it. I certainly don't want to have to by-pass a non functioning item that shouldn't FAIL in the first place. Maybe I shouldn't be riding a BMW because I really don't want to have to jerry rig the bike in some parking lot after it crapped out again. This is my first BMW so I may not be up to speed on my obligation to study motorcycle mechanics in order to survive.

I was actually hoping to just ride the thing and enjoy it. I think I'll inquire about an extended warranty.

jpooch00 · 08-21-2009, 02:59 AM

Quote:

Originally Posted by Delawarerider

Yeah and if you never start the bike, it'll last forever too. But WTF good is it. I certainly don't want to have to by-pass a non functioning item that shouldn't FAIL in the first place. Maybe I shouldn't be riding a BMW because I really don't want to have to jerry rig the bike in some parking lot after it crapped out again. This is my first BMW so I may not be up to speed on my obligation to study motorcycle mechanics in order to survive.

I was actually hoping to just ride the thing and enjoy it. I think I'll inquire about an extended warranty.

You're completely justified in your frustration IMO. I'm waiting on a 2010 myself and have been essentially doing a crash course in the basics on how to keep it running. No way can I afford $100/hr to pay some dealer tech to do half-assed repairs/tune-ups on it all the time for the general stuff.

As far as the major repairs are concerned, I've decided that when I'm negotiating the final deal on the bike, if they won't throw in the extended warranty for free, then I'm walkin'. Ya have to draw the line somewhere!

Delawarerider · 08-21-2009, 04:48 AM

I wish I had that wisdom when I was buying

08-19-2009, 08:08 PM	#1
Tantalum Kid ^OP n00b Joined: Aug 2009 Oddometer: 5	Fuel Pump Driver Failed on an 08 R1200GS 250 km into a weekend trip my bike wouldn't run. It would start, rev-out or idle for about 2 seconds, but wouldn't run. This happenned for about 30 starting attempts. After that all it would do is crank over, but not start. There were no warning or fault codes on the dash. BTW it was raining off-and-on all day. Thanks to BMW roadside assistance the bike was trucked to a dealer (about a 200 km tow). The dealer diagnosed the situation as a faulty fuel pump electronic controller - aka fuel pump driver - and a replacement is currently on order (2 week delivery). A little research revealed these controllers became wet due to a flawed o-ring seal. However, this situation was reported in 2005 and one might assume that this had been fixed for the 08 models. 1. Can anyone report this happenning to other 08-R1200GSs? 2. Is it possible to carry out a road-side replacement of the fuel pump electronic controller? Jim ___________________ '08 R1200GS '08 F650GS (twin)

08-20-2009, 01:31 PM	#5
JetSpeed ATAC Kfir Hack Joined: Nov 2007 Location: KPHF / Newport News Oddometer: 450	If your dealer will give you the failed part you can make an emergency bypass with it very easily and then stick it in your under-seat tray, that's what I've done after being turned into a pedestrian twice. BTW, once you have a bypass under your seat (and know how to use it) it will never fail again. __________________ Good Judgment Comes From Experience, Experience Comes From Bad Judgment. JetSpeed screwed with this post 08-20-2009 at 02:27 PM

08-20-2009, 01:40 PM	#6
Wallowa Beastly Adventurer Joined: Nov 2006 Location: NE Oregon Oddometer: 4,474	Anybody Contact BNW NA? Hey has anybody actually talked to BMW NA or BMW Motorrad about how the replacement controllers will stop the water damage generated failures of the controllers? I read the letter from Jan Urbahn from BMW NA to NHTSA. Check out his title: General Manager; Safety Enginering and Intelligent Transportation Systems! The letter is weak and doesn't specify how the controller will be modified to preclude these failures. I mean WTF....this is another absurd issue that should not be an issue. __________________ "In Wallowas" ==================== 2007 R1200GS Adventure " ...to explore off-road, alone in my case, way out in the boonies...that feeds the soul!"

08-20-2009, 02:30 PM	#8
JetSpeed ATAC Kfir Hack Joined: Nov 2007 Location: KPHF / Newport News Oddometer: 450	To be honest I don't believe that the fuel controller failures are due to water or corrosion, I think that the part fails due to overheating. __________________ Good Judgment Comes From Experience, Experience Comes From Bad Judgment.

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08-19-2009, 08:24 PM	#2
marchyman Talks to cats Joined: Jun 2005 Location: SF Bay Area Oddometer: 5,392	In the US it's a recent recall, number 09V319000 affecting '06-'08 R1200 GS.

08-19-2009, 08:24 PM	#3
leafman60 Beastly Adventurer Joined: Aug 2005 Oddometer: 1,026	Welcome to BMW ! Lol, my 07 had the upgraded o-ring and yet it leaked water, shorted out and stranded me on the freeway in Louisiana one hot summer day in rush-hour traffic. Be warned that even the "fix" from the factory may not work. Another thread outlines the procedure for by-passing a failed controller and direct wiring the pump like on the 1150 series. That by-pass may save a lot of pain and heartache the next time it lets you down.

08-20-2009, 01:03 PM	#4
JR356 Beastly Adventurer Joined: May 2005 Location: Way out West Oddometer: 3,187	Get this bypass cable from a fellow forum member,in case you have future issues: http://www.burnsmoto.com/bmw-fuel-pump-bypass-cable.php

08-20-2009, 02:02 PM	#7
Delawarerider Gnarly Adventurer Joined: Feb 2007 Location: Wilmington, Delaware Oddometer: 151	Mine failed last week. Dealer called today and its fixed. I love the fact that my '07 GS is being repaired, but why the hell does it keep breaking down. Fork seals, key antenna ring, rear main engine seal, two final drive seals and now this fuel pump problem. What will fail next?

08-20-2009, 04:41 PM	#10
Tantalum Kid ^OP n00b Joined: Aug 2009 Oddometer: 5	"Get this bypass cable from a fellow forum member,in case you have future issues: http://www.burnsmoto.com/bmw-fuel-pump-bypass-cable.php" Thanks for the info on the bypass cable, and thanks to all that replied. It's nice to know that I'm not alone. Also, this may explain the long delivery for the replacement fuel pump controller, i.e. high demand. The image of the failed controller shown on the page with bypass cable seams to have a lot of electronics inside. How complicated is this device? Especially if can be bypassed by a connection to the battery. Looks like its more than just a relay. Jim

08-20-2009, 07:45 PM	#13
Delawarerider Gnarly Adventurer Joined: Feb 2007 Location: Wilmington, Delaware Oddometer: 151	Yeah and if you never start the bike, it'll last forever too. But WTF good is it. I certainly don't want to have to by-pass a non functioning item that shouldn't FAIL in the first place. Maybe I shouldn't be riding a BMW because I really don't want to have to jerry rig the bike in some parking lot after it crapped out again. This is my first BMW so I may not be up to speed on my obligation to study motorcycle mechanics in order to survive. I was actually hoping to just ride the thing and enjoy it. I think I'll inquire about an extended warranty.

08-21-2009, 04:48 AM	#15
Delawarerider Gnarly Adventurer Joined: Feb 2007 Location: Wilmington, Delaware Oddometer: 151	I wish I had that wisdom when I was buying