How did you conclude the problem is the fuel pump and not, say, the ignition system? Just curious...

The BMW nomenclature is confusing, but there's the actual pump (referred to as "fuel pump"), currently over $400 from BMW, and there's an electronic controller (referred to as "fuel pump electronic") that's about $226 on Max BMW's parts fiche. The latter part was famous for corroding to jell-o on the early bikes. It sits on the top of the pump assembly, in a depression on the fuel tank that's good at accumulating water and encouraging corrosion. The updated unit is sealed better.

If you uncover the fuel pump and find a mass of gray-white corrosion and water where the electronic controller should be, that's probably your problem.

The function of the electronic controller is to regulate pump speed depending on the engine's demand for fuel. This is mostly for emissions, to reduce the amount of fuel being returned to the tank and splashing around and evaporating (note that on an '05 there is always some fuel coming back to the tank to operate the saughstrahlpumpe). Some people have contrived resistor networks that replace the controller and just run the pump at full speed all the time. Whether this shortens the pump lifespan is a matter of some debate. Some people riding into the middle of nowhere carry the resistors along just in case.

 

How did I come to that conclusion? When I cranked the bike first thing it would not start after few tries. The it finally start up and let it warm up.. took it out for a ride.. it sputtered few times before quitting on me for good. It will still crank but not fire up. I'm guessing it is fuel system issue and most likely fuel pump as this R1200GS seems to be prone to it for the 2005-2011 model. I explained the symptom to the dealer and they said it seems very logical that fuel pump would be the culprit but obviously it is not official yet.

And this is one of the moment I wish I didn't sell my never-used GS-911 that I bought in case I have any issue with my 2001 F650GS. Oh Well!

Thanks very much for detailed reply and I'll inspect the fuel pump on Thursday. Send my Colombian GF off at the airport today then adjustor appointment at the beach house tomorrow.. doctor appointment on Wednesday,, so Thursday if it is sunny. Again, thanks and I'll report back my finding. I am also planning to see if there is a fire from both spark plug. Just not sure how I can see if fuel injector is spraying fuel?? (I read about that in old thread posted in 2007).

 

OH!! I forgot to mention I did think possibility of bad gas because I put 4.2 gallons of gas in less than 10 miles before the symptom. Maybe water in gas?? Gas was from the store at the beach and with Hurricane Florence it is unclear how many people pumped the gas?? I put in Premium and it is $3.59 vs $2.49 regular. I had thought about siphoning gas out and put fresh gas in??

 

Sounds like the fuel pump controller...I had the same symptoms when mine pouched out,3 years ago..it looked brand new from the outside,but was corroded badly inside..you need to remove it and open in up to know for sure..I also thought I had bad gas as it would randomly start but never get me far before cutting out...easy swap

 

Yes check first the fuel pump controller. I had a similar issue with my 08 GS. It is first check I would do. Lot of suggestions if you google it

 

Go to burnsmoto.com and buy a fuel pump by-pass cable for $35.00

That could help with you trouble shooting. I carry one on my bike.


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If you have reason to suspect the gas is bad, draining and replacing it is always a good idea.

Also, a really really easy check I haven't heard anyone mention: turn the ignition on. Don't press the starter button or anything. Do you hear the fuel pump spin for a few seconds as it pressurizes the system? If not, you've at least isolated the problem to the fuel pump and/or controller. If you do hear the pump running and the bike refuses to start (or even fire briefly), then I'd look at ignition or fuel injection problems (or really contaminated gas), vs. the fuel pump. Another check you could do is to pull a spark plug and see if it's dry or wet with fuel--if it's the latter, again, you're not getting a spark.

BTW, if it turns out you have a good controller and a bad pump (something you can determine by installing the jumper--either from Burns, or make your own; instructions can be found online), Beemer Boneyard sells a replacement Bosch pump for less than half what BMW charges. The only challenge is that you'll have to marry the pump to the BMW flange and outlet assembly. But this shouldn't be particularly hard.

 

I am deaf so I had my neighbor over to listen to the fuel pump when I turned bike on. He said it was making humming sound for few seconds then stopped. When I turned bike off, short humming sound then stopped. When I tried to crank the bike it feels as if it wanted to start but not firing up. Your thought??

I'm heading out to wal-mart now. I'm going to buy fuel siphon and try to siphon gas out and try fresh gas just to see if that help although I doubt it.

 

I also had the fuel pump controller go out on my 2005 GS and it acted up the same way, it is far more likely to be the controller than the pump itself, if it were me I would order and replace the controller and probably get the burnsmoto cable as well to pack on the bike just in case.

 

Wal-mart didn't have fuel siphon so look like that will have to wait.. might not even need it.

Was able to get spark plug on right side out.. but had a little trouble with the socket I was using.. a little short but managed to get it out somehow. Cranked the bike and a little came out of the cylinder hole.. smell fuel. Plug was firing so ignition not the issue on right side. Plug seems a little dry but seem ok. Wonder if I should go ahead and replace it?

Had a little trouble getting plug back in so I stopped right there. went out to get longer and thin socket. 16mm wasn't in stock but 5/8" socket was and work just fine. Oops! I needed the 1/2 to 3/4" adapter and I know I had it somewhere.. so I'm gonna try to find it tomorrow.

In meantime, the burnmoto plug came in but it seems I was a little confused with how the website work. I didn't see the pull-down that would allow me to get the plug and cable. At least I already have the red & black 16ga wire so I am going to get it set up tonight and ready to test the bypass tomorrow to confirm it is the controller.

 

Yesterday was my mother's birthday.. so didn't do anything.. today found the problem.

https://youtu.be/7MoSD2CoA6s

So far, the price for Fuel Pump Controller is $226.. do anyone know a better price? If not, then no problem..

 

Oh and by the way, NON-ABS on my R1200GS. Went with something more simple and less complicated. I like it simple. lol

 

New fuel pump controller arrived and I see the difference. See old vs new.

Top is old/bottom is new

Left is new, right is old.

I see different in design and color.. I am not accusing my dealer of lying but I am wondering if the fuel pump controller changed design in last few years?

The difference is location of the wires.. on old one, wires come out in same place and now there is hole which may be how the controller got damaged from condensation but on new one wires are from different location which may prevent hole from being created and minimize the risk of damage?

Dealer said that my R1200GS had recall service 4 years ago so I'm curious to know more.. and what's the chance they used Fuel Pump Controller with original design instead of new design during the recall service or did the design changed again since the recall service?