Right side gas tank flange cracked/leaking '05 GS

[Still CAL]

Posting in Hexheads as I think there would be some similarity amongst fuel tanks in these models. Mods, move to the GS section at your pleasure. I also posted on Advrider.

 

Purchased last summer with 40k on the clock. Had a smell of gas that I traced to the right side flange that is cracked around the QD bung. I replaced the QD with a metal one and gently screwed it in, using the sealant provided, but it's still oozing from the cracks so I'm replacing the flange. No metal ring around the bung so the flange is probably original.

Since I can't see what's behind the flange I didn't want to force it and break something pricey. Or at all. In the end I decided to see if there was enough room to release the clip holding the jet pump to the back of the plate; that did the trick. I was then able to get plenty of room to swap over the two drain/overflow lines. Reinstalling the pump was also a non-issue, as I had enough room to hold it between two fingers and get it to clip on to the new flange.

That jet pump must be a booger to install at the factory. The outlet hose hooks around the bottom inside of the tank to push gas over to the fuel pump on the left side. Clymer said to pull the fuel pump to disconnect that line, but there was nothing there to disconnect. Oh, there is a float on the pump, is that just for a low fuel light?

So anyway not a hard job, all in all. A hammer and screwdriver plus a few light taps got the retaining rings moving. I used a thin blade screwdriver to gently lever the flanges loose, and a very thin coat of silicone grease on the seals when reinstalling. I also discovered the filler drain clogged with Florida sand from its former home, so a good thing I got that opened up.

 

[dirtrider]

13 minutes ago, Still CAL said:

Posting in Hexheads as I think there would be some similarity amongst fuel tanks in these models. Mods, move to the GS section at your pleasure. I also posted on Advrider.

 

Purchased last summer with 40k on the clock. Had a smell of gas that I traced to the right side flange that is cracked around the QD bung. I replaced the QD with a metal one and gently screwed it in, using the sealant provided, but it's still oozing from the cracks so I'm replacing the flange. No metal ring around the bung so the flange is probably original.

Since I can't see what's behind the flange I didn't want to force it and break something pricey. Or at all. In the end I decided to see if there was enough room to release the clip holding the jet pump to the back of the plate; that did the trick. I was then able to get plenty of room to swap over the two drain/overflow lines. Reinstalling the pump was also a non-issue, as I had enough room to hold it between two fingers and get it to clip on to the new flange.

That jet pump must be a booger to install at the factory. The outlet hose hooks around the bottom inside of the tank to push gas over to the fuel pump on the left side. Clymer said to pull the fuel pump to disconnect that line, but there was nothing there to disconnect. Oh, there is a float on the pump, is that just for a low fuel light?

So anyway not a hard job, all in all. A hammer and screwdriver plus a few light taps got the retaining rings moving. I used a thin blade screwdriver to gently lever the flanges loose, and a very thin coat of silicone grease on the seals when reinstalling. I also discovered the filler drain clogged with Florida sand from its former home, so a good thing I got that opened up.

 

 

 

 

 

Morning  Still CAL

 

That should have been covered under the original BMW recall & is probably covered again as a full unit replacement under the current (new) BMW recall.  (on the GS I'm pretty sure the recall covers both the electric pump side & the sucking jet pump side)

[w2ge]

What dirt rider said...

 

in my recent recall notice it did note that it’s recalled, but parts not available yet...  awaiting second notice that parts are available for recall to be performed. 

[Still CAL]

I was thinking that but when I asked on the recall thread I got no response, so figured it was only the pump. Anyway, it's done.

[dirtrider]

5 minutes ago, Still CAL said:

I was thinking that but when I asked on the recall thread I got no response, so figured it was only the pump. Anyway, it's done.

Morning  Still CAL

 

If you bought that motorcycle used then be sure to go to BMW  web site & register your VIN so you get all the recall notices for that motorcycle mailed directly to you. It might eventually reach you through the DMV records but they come quicker if you are registered with BMW.

 

With you already replacing that suction pump BMW usually includes a reimbursement option so you can get some money back if you needed to replace the pump on your own dime due to safety concerns. 

 

I will have to look when I get home but I'm pretty sure that sucking pump is also covered on the 1200 GS.

[dirtrider]

Afternoon Still CAL

 

Looks like the latest BMW recall (20V-471)  does include the 1200GS  auxiliary fuel pump as applicable.    Covers the 1200GS, 2005-11 & the 1200GS Adventure, 2005-11.

 

 

[Still CAL]

Thanks, I’ll register with the Motorwerks  Boys.