GS-Riders International

... caused my bike not starting (no error message in the display). According to my BMW workshop the turquoise coloured silicon sealing had failed



and water entered the fuel pump controller, no. 3 in the graphic:



The part has been changed under warranty. I also received the advice leaving the cover off.



I'll better look for water-proofing the cover.

Since my bike is still covered under warranty, I did not bother diagnosing the problem myself. I called the BMW emergency service. The bike was towed away to the local agent. A few working hours later I could pick her up already. Even though this was stranded at the road-side, I have only positive feelings about the response from the BMW emergency service team.

Thanks for the tip! The BMW workshop has exchanged the controller with a new one. But I will redo it in the fashion you mention. Anyway not bad to know what's underneath.

Did you know this? Together with the ring antenna issue fuel controller failures seem to be the two most consistent issues since 2004. See this thread at ADVRider http://www.advrider.com/forums/showthread.php?t=57153. Post no. 8 gives a competent summary, in case you don't like reading the entire New Testimonial. The UK GS-ers did a survey:

Failure reports in the UK:
7 known failures in 2004
11 known failures in 2005
25 known failures for 2006
50 known failures in 2007
70 known failures so far in 2008 (by Aug)
source: http://www.ukgser.com/forums/showthread.php?t=143272


CAUSES

There are two different schools of thoughts:
1. One group thinks it is caused by water breaking in. BMW has improved the sealing (old back colour, new turquoise). From '08 the mounting of the fuel pump plattform is different, so that water will rinse off instantly an has no chance of forming a big puddle.
2. The other group believes it is a heat problem. The controller throttles the fuel pump about 80 % right after the bike started. Ater start the controller throttle the fuel pump from about 12 V to 9.7 V. Therefore, the controller has to dissipate a lot of heat.

Note: Several people found no signs of water intrusion, but burned circuit boards, just like the one shown on the pic below. Fact is also the heat sink design has been changed (in 2006 I believe). So the heat is the more likely issue, in spite of what BMW says. Mind you, a BMW supplier is not able to calculate sufficient heat dissipation fin surface!

Burned fuel pump controller

source: member xover at http://www.advrider.com

Rethinking about my conservation with the BMW service man, I've received two tips from him:
1. Wipe the area dry from time to time
2. Leave the cap off.
After BMW fixed the sealing, overheating seems the real issue here.


FIXES

1. Fix - Controller bypass

- Bare the two cables as shown


- Connect them to the two wires on the blue plug from the controller
- Observe the cable colours

fix by Tim Cullis at http://www.ukgser.com


2. Fix - Controller jumper cable

- Store it under your seat.

fix by Anton Largiader at http://www.advrider.com

Video Installation Demo: clicky. Source: Video as posted by AndyW1200GS on Youtube.


3. Fix - Spare Fuel pump controller
- New module BMW part no. 16147694378, about US$ 135 / Euro 90 .

The GS '08 has a different tank shape. The fuel pump area is slanted now, no cover, and enforced wires. This allows for easy water drainage and provides better cooling for the fuel pump controller.



The '08 GSA retains the older tank shape, AFAIK. I don't know more details about how the fuel pump area looks like.

This is already an older one, just found it on ADVrider.

Campaign ID#: 05V082000Mfg's Report Date: Feb 21, 2005
Component: Fuel system, gasoline: Delivery: Fuel pump.
Models Affected: '04 — '05 R1200GS
Potential Number Of Units Affected: 3,084
Summary: On certain motorcycles, the defect involves a water leak around the fuel pump that is integrated within the fuel tank. An O-ring seal attached to the pump's electronic housing does not meet specifications and water can bypass this seal and contact the pump electronics.
Consequence: Engine stalling, or a failure to start, could occur without prior warning. If stalling were to occur while the motorcycle was being driven, the rider would be unable to maintain speed or accelerate and a crash could occur without prior warning.
Remedy: Dealers will replace a sealing ring. If the fuel pump electronic unit is corroded, it will be replaced. The recall began May 9, 2005. Owners should contact BMW at 1 (800) 831-1117.

Would it be useful for you calling the above number, asking what is the status like for your '08?

Quoted from "ghostrider1964"

I heard about this in the earlier GSs, what about 07 and 08? Is it still an issue? Just trying to decide if I need to have a bypass cable rig. These that have failed, are they all because of water leaking in? And finally were the bikes immersed or was that just rain getting in?

There is now a recall for the '07 GS in Germany.

Was this the previous service advisory related to the seal? There is a new one, which only concerns certain '07 models.

There we got it. This time it is only the '07 model, and this time the electronic unit will be changed. They are trying to keep things low profile.

Shouldn't BMW feel ashamed having such a lousy suppliers management? Pump controller, ring-antenna, batteries ... these three are very long running issues, simple and avoidable.

I am looking for a small waterproof 12 V fan, the size like those found on graphic cards or CPU's. Does anyone know a source?