Fuel pump controller bypass jumper cable

[Plasterman]

Question. I have a 2009 R1200RT. Do I need to be concerned about failure of the fuel pump controller? If so, I would like to make my own bypass jumper cable. Can someone tell me that part number for the plug or the wire with the plug? What is the cheapest way to make one of these?

 

Thanks

 

Tom

[David13]

You don't need to be concerned. Particularly if you have the bypass.

The commercially available cables feed out and into the cigarette lighter, or accessory socket, like some like to call it.

Maybe the other connector is not available.

If yours looks corroded, you could get a new one and use the old functioning unit as a bypass. Or make your bypass cable from the old one, if it no longer works.

You are better off familiarizing yourself with the issue prior to failure, rather than after, like me.

dc

[Guest Kakugo]

Considering the amount of time it takes to do a by-pass or replace the FPC is definitely worth having a spare aboard.

 

Your cheapest option is to ask your local dealer for a failed FPC and recycle the connectors: FPC Bypass Guide . They don't bother sending them back anymore, haven't in at least four years so it's just trash to them.

 

Second cheapest option is buying a ready made bypass cable from Burns Moto. It's $35 plus shipping. The genuine plug is around $25 if memory serves me right. You can also order the plug alone ($23) and fit a quick connector to run it directly from the battery.

 

Or splurge out like me and buy a spare FPC to carry around.

[mig]

mine failed last winter and I used the old one to make the jumper.

I ride year round and you will find that if you ride in the rain water will pool on the fuel control module. Eventually mine seeped and burned out the unit. I installed the new one with a thin coat of silicone to help seal , but not make it impossible to remove if needed. The jumper took less than an hour to make. I carry that all the time. the good thing is that all you have to do is remove the left side panel to access the module. take a look one day.

[LPOL]

"On BMW R1200GS, R1200GS Adventure, R1200RT, R1200ST, R1200R, F800GS and F650GS-twin motorcycles, the fuel pump controller can fail due to water infiltration or because of a design flaw, limiting heat sinking, leaving you stranded. Using the accessory socket or an SAE battery connector and this cable as a temporary fix, you can bypass the failed controller and get back on the road."

 

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

 

Installation instructions:

http://burnsmoto.com/bmw-fuel-pump-b...structions.php

 

MY set of instructions from the Burns video which I typed out and take with me: Feel free to COPY!

 

Fuel Pump Controller BYPASS Installation Instructions

 

1. Remove the left side gas tank cover.

 

2. Remove the black fuel pump cover.

 

3. With a small flat screw driver...pry open the retaining clip and remove the power to the fuel pump controller (

4. With a torx socket (size T-20) remove the screws that are holding the fuel pump controller to the top of the fuel pump.

 

5. On the rear screw...I found it easier to use a torx T-20 screw driver.

 

6. With a small screw driver...pry up the fuel pump controller. Look inside and you'll see the BLUE connector.

 

7. Use your screwdriver to squeeze the tabs on the blue connector to make it easier to remove.

 

8. Now...take your fuel bypass pump cable and align that connector to the top of the fuel pump connector...and connect it.

 

9. Insert the Powerlet connector into your accessory socket.

 

10. Now...start the bike.

11. Tuck the cable under the side covers...so they're out of the way.

12. You're back on the road.

[dirtrider]

Just a caution on using fuel pump jumper cables--

 

A fuel pump jumper cable or by-pass harness is a great idea to carry for times when your bike or a friends bike has a sudden FPC failure.

 

Just keep in mind that some of these cables are set up to use the STOCK (ZFE controlled) power outlet socket.

 

Here is where the problem lies-- the fuel pump in the hexhed can draw more power then the stock (ZFE controlled) outlet can supply without tripping the internal circuit breaker. Some earlier bikes only have a 5 amp ZFE protected outlet while the later bikes have 10 amp protection. Even 10 amps isn't quite enough at full pump load.

 

The best way to use an FPC bypass harness is through a direct battery connection like through an SAE plug or battery direct Powerlet plug.

 

[Paul Mihalka]

On my R1200GS I have a fuse block that is in part controlled by the ignition switch. When I get my pump jumper it will be hooked so it starts and stop with the ignition.

[I812]

Thanks for making my day DR!

[Paul Mihalka]

I was lazy and did not get a controller bypass cable and I'm going on a loooong ride. Removing the fuel pump controller I think there is a blue and a yellow cable going to the pump. Which one is + and which one is - ? With this information I can improvise if I have to.

[BrianM]

Give this a try

 

http://www.motorcycleinfo.co.uk/index.cfm?fa=contentGeneric.nvxszdkebklxuaer&pageId=428065

[Paul Mihalka]

Thank you. By reading it now I know that blue is ground and yellow is hot. With this I can make it work if I have to (hope not needed).

[marcopolo]

Given that the re-designed fuel pump controller is relatively inexpensive (and installation is very quick), why not just install a new one as preventive maintenance? That's what I did a few months back before heading off on a one-month road trip to the UnRally and beyond. Cheap insurance to avoid ruining a holiday.

[David13]

And carry the old one as your spare.

That is exactly the idea.

dc

[Dave_in_TX]

I was lazy and did not get a controller bypass cable and I'm going on a loooong ride. Removing the fuel pump controller I think there is a blue and a yellow cable going to the pump. Which one is + and which one is - ? With this information I can improvise if I have to.

 

I took the same approach with my 07 RT but I carried four posi-taps and a short length of wire with me to make improvisation easier. Had the bike for 140k miles and never had a problem with the controller.

[RedMac]

What's the part number for the new controller.. I'd like to replace mine..

 

Thanks

M

[BrianM]

Real eom.

 

http://www.realoem.com/bmw/select.do?kind=M&arch=0

[marcopolo]

What's the part number for the new controller.. I'd like to replace mine..

 

Thanks

M

 

I got one in May of this year. The part number is: 16 14 7 720 776.