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Old 09-03-2012, 02:12 PM   #16
JRWooden
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Location: The great state of confusion
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On the one page of troubleshooting notes I keep on my bike at all times I have it written (so it must be true)

That "Joel said":
There are only two sensors that were absolutely required for the bike to run (notice I didn't say "run well" I just said "run")
They would be the TPS and the crankshaft position sensor. If the BMS-K gets an "open circuit" reading to any other sensor it goes into "limp home" mode and just does the best it can do without input from that sensor. Unfortunately sometimes the sensors fail in a "believable state" such that the BMS-K thinks that the signal is valid which causes confusion.

I would "hot-wire" around the pump controller and unplug the pressure sensor
(not both at the same time ... try one then the other then both ... see what changes)
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Old 09-04-2012, 12:35 AM   #17
jlpp OP
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Thanks all. More detail and info to come after installation but quickly..

Today we managed to find and buy a new Bosch fuel pump in Bishkek that looks identical except for the part number. We have some concern about the fuel filter too though. We're wondering whether the filter might be choked on bad central asian fuel and whether this made the original pump struggle to the point of overheating. If the filter is bad then the new pump might fail quickly. So we bought a fairly generic fuel filter too. It may not fit in the OEM pump/filter/controller harness but if we have to punch a hole through the original filter material and add this new filter in-line outside the tank with some weird colostomy bag like hose hanging out until we can get to a BMW part then we might do this.
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Old 09-04-2012, 05:06 AM   #18
jlpp OP
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Ok, new fuel pump is installed and bike runs and rides fine in the 3 kms we've ridden so far. Here's some info on the pump and Bishkek in case others are interested.

Firstly, the original US 2009 F800GS fuel pump we pulled out is labeled:

0 588 453 439
Bosch
12v 01027
Made in Germany

The replacement part that we found in Bishkek is labeled:

0 580 453 453 (yes, same # twice)
Bosch
12v 10607
Made in Germany

We found the replacement part (and bought two) at a shop that has Bosch placards and flags all over the front. We also got some Motul injector cleaner there:

EVI Autocenter
42.865440,74.567480
Corner of Lev Tolstoy St. and Asanaliev St.

The new part is basically identical from the outside but I don't know the specs on pressure and liters per minute. But again, it's installed and working so far.

Next we went to the only motorcycle shop we heard of in Bishkek to see what kind of other shit we could buy. It's run by a guy named Dima and his wife. They've got helmets, armor, filters and other parts:

"Dima Biker"
42.882055,74.5235277
One container of many in the Kudaybergen Auto Bazaar (pronounced Kudaibergen Afto Bazaar)

After using his mouth to blow air through the original fuel filter, he believed that Tajik and other central asian gas had clogged it up and that the replacement fuel pump would also die if I didn't also replace the filter. We looked around the bazaar and went back to EVI to see if we could find a replacement filter but didn't find one. Instead we picked up a couple other types of fuel filters and hose that we could jury rig if we have find the new pump is struggling. I didn't feel any difference in the amount of pressure needed to blow air through the original filter vs. the new one so we left the original in place for now.

We did the job of replacing the pump (and also new tires we've been hauling since Turkey) at the home of a local biker, Alexi. Actually I don't think I met Alexi but I met a couple of his friends and his son. In particular, a fellow named Constantine helped us quite a bit. This place was recommended by a Japanese biker who's been on the mend in our guesthouse here in Bishkek after an accident a couple months ago. None of them speak english but no problem.

"Alexi Biker" (and Constantine)
42.881468,74.631522
212 Saratovskaya St.

Lastly, here's what I found when searching online for alternatives to the original pump. None of it has been confirmed by me so some of it may be speculative:
"Opel Tigra Vectra B Zafira 99-05 FUEL PUMP OPEL 815037"

Pump on Alibaba:
Replacement for:
BOSCH part #: 0 580 453 465
OPEL part #: 815037 815039 9120218 9200109
S.I.D.A.T. part #: 70027
VDO part #: 983 784 024 (993? 784? 025? A?)
Pressure: 3.8 BAR
Volts: 12v
Vehicle Manufacturers:
Opel Astra G
Opel Corsa B
Opel Tigra B
Opel Vectra B

High Flow Performance (brand)
Part #: HFP-382
Overall Length (tip to tip): 4 1/2" (11.5cm)
Length of Pump Body Metal Case: 2 5/8" (6.6cm)
Pump Body Diameter: 1 1/2" (3.8cm)
Inlet Diameter: 5/16" (0.8cm)
Outlet Diameter: 5/16" (0.8cm)

Bosch #s:
0580453447
0580453420
0580453431
0580453439

China pumps - Krauf #s:
770002w
77093w
770b037
EDIT (10/21/12):
Found the following information on a few pages when searching for Bosch 0580453453. Some places no pump manufacturer is listed. On Amazon it says Power Pro:
Item# NSFP-01
Also
Item# C314

Product Description
AC DELCO: EP389 EP391 DELPHI: FE0117 FE0118 BOSCH: 0580453453 0580453407 0580453449
Brand New OEM Quality Fuel Pump , PRESSURE: 3BAR SHUTT-OFF PRESSURE: 6BAR WIDE OPEN FLOW: 150L/H VOLTAGE: 12V Will Fit List The Vehicles Below :

1995-1998 Nissan 200SX
1998-2001 Nissan Altima 2.4L
1995-1999 Nissan Sentra
1993-1996 Ford Crown Victoria 4.6L
1995-1998 Ford Contour 2.5L
1995-1998 Mercury Mystique 2.0L
1993-1996 Ford Probe 2.0L
1995-2000 Ford Explorer 4.0L
1995-1998 Ford Contour 2.0L
1993-1996 Lincoln Town Car 4.6L
1998 Ford Ranger 2.5L
1993-1996 Mercury Grand Marquis 4.6L
1994-1995 Ford Crown Victoria 4.6L
1993-1997 Ford Probe 2.5L
1998 Mercury Villager 3.0L
1998-2002 Mazda 626 2.0L
1994 Ford Tempo 2.3L
1994 Mercury Topaz 2.3L
1996 Ford Explorer 5.0L
1997-1998 Ford F150 4.2L
1994 Mercury Topaz 3.0L
1994-1997 Ford Mustang 3.8L
1997-1998 Ford F250 4.6L
1999-2002 Ford E150 4.6L
1994 Ford Tempo 3.0L
1997-1998 Ford F150 4.2L
1998 Ford Ranger 3.0L

BOSCH : 0580453408 0580 453 408 0580453427 0580 453 427
Fiat : 60812839 6081 2839 , 7789626 778 9626 , 46480607 4648 0607 464806070 4648 06070 , 606519690 6065 19690
Alfa Romeo: 46480607 4648 0607
GMC : 93238459 9323 8459
Reference Part Number : 0580453408 0580 453 408 0580453427 0580 453 427
Brand New OEM Quality Fuel Pump Will Fit List The Vehicles Below :

Make & Model Engine Code Year KW HP cc
ALFA Romeo 155 (167) - 1.6 16V T.S. AR 67601 05.96-10.97 88 120 1598
ALFA Romeo 155 (167) - 1.7 T.S. AR 67103 04.93-04.96 83 113 1748
ALFA Romeo 155 (167) - 1.7 T.S. (167.A4D, 167.A4H) AR 67105 04.93-04.96 85 115 1748
ALFA Romeo 155 (167) - 1.7 T.S. 16V AR 67106 05.96-10.97 103 140 1747
ALFA Romeo 155 (167) - 1.8 T.S. Sport (167.A4A, 167.A4C, 167.A4E) AR 67101 AR 67102 02.92-04.96 93 127 1773
ALFA Romeo 155 (167) - 1.8 T.S. AR 67101 02.92-06.93 95 129 1773
ALFA Romeo 155 (167) - 2.0 T.S. (167.A2A) AR 67202 04.93-02.95 104 141 1995
ALFA Romeo 155 (167) - 2.0 T.S. (167.A2) AR 67201 02.92-04.93 106 144 1995
ALFA Romeo 155 (167) - 2.0 T.S. 16V (167.A2G) AR 67204 03.95-10.97 110 150 1970
ALFA Romeo 155 (167) - 2.5 V6 (167.A1C, 167.A1E) AR 67302 AR 67303 05.96-10.97 120 163 2492
ALFA Romeo 155 (167) - 2.5 V6 (167.A1) AR 67301 02.92-04.96 121 165 2492
ALFA Romeo GTV (916C_) - 2.0 T.SPARK 16V (916.C2__, 916C2C00) AR 16201 AR 32310 06.95-09.00 110 150 1970
FIAT COUPE (FA/175) - 1.8 16V 183 A1.000 03.96-09.96 96 131 1747
FIAT COUPE (FA/175) - 2.0 16V 836 A3.000 04.94-08.96 102 139 1995
FIAT COUPE (FA/175) - 2.0 16V Turbo 175 A1.000 04.94-08.96 140 190 1995
FIAT COUPE (FA/175) - 2.0 20V Turbo 175 A3.000 10.96-09.00 162 220 1998

Will report back on the new pump when I've ridden a few hundred kms.

jlpp screwed with this post 10-20-2012 at 07:15 PM
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Old 09-04-2012, 05:46 PM   #19
JRWooden
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If the old saying: "When the plan fails, the adventure begins" is true ... your adventure is well under way!

Thanks for very informative post, I hope your problems are resolved, keep us posted!

Based on your issues and watching the "long way down" videos ... I'll likely pack one of these or something similar on my round-the-world tour ... (that I hope to take some years hence):

http://www.amazon.com/Mr-Funnel-AF1C.../dp/B000SOFLHK
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Old 09-05-2012, 02:21 PM   #20
justinparke
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Update

JLPP installed new fuel pump.

Note: no additional diagnostic/status information after this due JLPP's lack of internet connectivity.
JLPP riding through rural Kyrgyzstan trying to make it through Pakistan to India before visa runs out.

Input courtesy of Bob's BMW tech (thank you guys!) based on ADVRider post above + latest status:

Sure sounds like a fuel issue. Your email doesn’t state if the problem persists with the new pump, I hope it doesn’t. I have seen the pumps overheat after an extended ride. To properly diagnose it you are gonna need a multimeter. These bikes have a fuel pump controller that varies the voltage to the pump to provide the correct pressure. Under the seat on top of the pump assembly sits the controller. Under the controller are the 2 output wires to the pump. You need to take a voltage measurement at the output of the controller when the bike is not starting to see if voltage is dropping off or exists at all. While cranking you should see over 10v. there is a possibility that the controller is popping out or the pump. So hopefully you can eliminate one. You can also jump the pump w 12v with the controller disconnected to test the pump as well. Hope this helps.

Awesome BMW motorcycle shop to help out in a pinch with limited information from the field (Bob's BMW)... really appreciate the help!
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Old 09-19-2012, 01:51 PM   #21
jlpp OP
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No issues with new pump

We've ridden from Bishkek, Kyrgyzstan to Islamabad, Pakistan and no issues with the replacement pump so far. Just a quick update while I was thinking of it...
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Old 10-07-2012, 06:10 AM   #22
jlpp OP
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Replacement pump died after about 2,500 miles

Got as far as Jammu, India and the replacement Bosch pump died (part #: 0 580 453 453). That was about 2,500 miles of life. I stopped to fuel up and the bike would fire up after. The engine would turn over but not start. Different behavior from the original pump, which failed slowly, seeming to overheat.

I replaced the pump with another of the same and will report back if and when it fails.
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Old 11-12-2012, 08:29 PM   #23
njoytheride
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Location: WESTERN AR
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I may be joining the dying fuel pump family soon. Started a few years ago on a hot day. Died three or four times pullng up to a stop sign. would restart but died again soon afterwords. Hasn't happened again until this summer out in Colorado. This time going down the road at 60 mph it would die and then restart. This week I was riding close to home and it died at leat 30 or fourty times on the way home. Restart and then die again. Topped of with fuel and added Chevron techtron and it would still cut out a lot but limped home. What is the lasted update on this issue?
Any information would be helpful. Thanks, Craig
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Old 11-13-2012, 01:53 AM   #24
JRWooden
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Do you know that it is the pump and not some other screw-up?
(I'm just asking .... clogged injectors seem to be another common fuel system issue )

Anyway, I think the best news is that if it truly is the pump that there are now aftermarket units available at better prices! Seem to be in the $40 - $70 range. Links are to ebay auctions, but there are other sources ...


http://www.ebay.com/itm/OEM-Intank-F...item3f1daa476e

http://www.ebay.com/itm/New-Intank-E...item2a1e71deaf
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Old 11-13-2012, 04:51 AM   #25
guzzimike
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Quote:
Originally Posted by njoytheride View Post
I may be joining the dying fuel pump family soon. Started a few years ago on a hot day. Died three or four times pullng up to a stop sign. would restart but died again soon afterwords. Hasn't happened again until this summer out in Colorado. This time going down the road at 60 mph it would die and then restart. This week I was riding close to home and it died at leat 30 or fourty times on the way home. Restart and then die again. Topped of with fuel and added Chevron techtron and it would still cut out a lot but limped home. What is the lasted update on this issue?
Any information would be helpful. Thanks, Craig
Have a squiz at this
http://www.advrider.com/forums/showthread.php?t=834239
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Old 11-13-2012, 08:48 PM   #26
Kiwi Tinkerer
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Coil failure?

Gidday, assuming that the problem is not the fuel pump.
It could be that one of your coils is faulty.

I was in a week long tarmac car rally last month here in NZ (www.targa.co.nz)
We had a similar symptom in the wee Renault Megane RS225 we were running.
Once the car was hot we would get a miss under heavy load. There were no errors in the daignostics to show this fault. We were away from the main cities so we purchased a single coil from a car wreckers. We swapped the coil out one at a time until we removed the miss. Fixed.

The offending coil was breaking down when it was hot and under load.

Certainly worth a try. if you can get one. Maybe borrow one from another bike to test. I am not sure if the coil is the same for a bunch of bikes. Maybe check max BMW parts fische.

Good luck.
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