BMW Motorcycle Fuel Pump Bypass Cable - BMW Luxury Touring Community
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post #1 of 17 Old May 17th, 2017, 7:54 am Thread Starter
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BMW Motorcycle Fuel Pump Bypass Cable

Was thinking of buying a BMW Motorcycle Fuel Pump Bypass Cable for my 2007 R1200RT as a precaution in case of a failure when am touring.
I was wondering if it is safe to plug it into the accessory socket, considering it only allows 5 amps?
I wondering if the fuel pump draws more than 5 amps?

https://burnsmoto.com/products/bmw-m...p-bypass-cable

Advice appreciated.
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post #2 of 17 Old May 17th, 2017, 8:11 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

As I did, I just purchased a new one, installed it, and threw the old one in the side case. Or, you can buy a new one and store it in your side case for when and if the old one goes out. If the old one breaks, I cannot see the purpose of installing the bypass cable (spending funds) and then having to buy (more funds) a new fuel pump controller.

Mike Trevelino
Williamsburg, VA
2008 RT
2000 LT - Totaled at 99,960 miles


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post #3 of 17 Old May 17th, 2017, 8:46 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

Quote:
Originally Posted by corrcullen View Post
Was thinking of buying a BMW Motorcycle Fuel Pump Bypass Cable for my 2007 R1200RT as a precaution in case of a failure when am touring.
I was wondering if it is safe to plug it into the accessory socket, considering it only allows 5 amps?
I wondering if the fuel pump draws more than 5 amps?

https://burnsmoto.com/products/bmw-m...p-bypass-cable

Advice appreciated.
You can do what Mike suggest, or if you search this forum, in the RT section, you will find plenty of data of what and how to prep, without buying that cable! I had my '07 wired up ready to go, in the event that the FPC ever died, but never had to use it.

Pad. Gajajiva
Solon, OH, USA

2015 R1200RT (San Marino Blue Met.)
2014 R1200RT (Quartz Metallic Blue - Returned to BMW)
2007 R1200RT (Sold!)


Once Upon a Time........
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1960 Triumph Bonneville (T120)
1960 Triumph Thunderbird (6T)
1952 Triumph Thunderbird (6T)
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post #4 of 17 Old May 17th, 2017, 8:47 am Thread Starter
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Re: BMW Motorcycle Fuel Pump Bypass Cable

Fair point, that is my other option, just more expensive.
I think I'll just buy a new controller!
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post #5 of 17 Old May 17th, 2017, 9:10 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

My toolkit includes about four feet of 16 gauge wire, four Posi-Taps, and a printed copy of the attached wiring reference, which is also stored on my phone. Together, I should be able to rig a bypass using the existing wiring, but without cutting up my wiring harness. The parts are cheaper than the burnsmoto jumper, take up a little less room than the jumpers I've seen and have alternate repair uses.
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File Type: pdf FPC Bypass.pdf (39.8 KB, 39 views)

Larry
2006 R1200RT
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post #6 of 17 Old May 18th, 2017, 7:56 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

There are (were) many references to guide you in making a FPC bypass cable at home. Not a big deal. Google will find them and maybe Youtube....

But I digress... Take the left side tupperware off and look at your fuel tank and the area around the FPC. The issue was/is cracks in the flange "thingy" (sorry for the technical term).. but if its cracked or leaking or smells of fresh fuel go to the dealer. I think there is/was a program or maybe Service Bulletin on the matter with free repairs... heck, you can even use the phone and call them.

or am I imagining all this? I am pretty sure I had a tiny crack in the collar of my '05 and that the dealer fixed it chop-chop... no charge.

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post #7 of 17 Old May 18th, 2017, 10:29 am Thread Starter
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Re: BMW Motorcycle Fuel Pump Bypass Cable

Quote:
Originally Posted by hopz View Post
There are (were) many references to guide you in making a FPC bypass cable at home. Not a big deal. Google will find them and maybe Youtube....

But I digress... Take the left side tupperware off and look at your fuel tank and the area around the FPC. The issue was/is cracks in the flange "thingy" (sorry for the technical term).. but if its cracked or leaking or smells of fresh fuel go to the dealer. I think there is/was a program or maybe Service Bulletin on the matter with free repairs... heck, you can even use the phone and call them.

or am I imagining all this? I am pretty sure I had a tiny crack in the collar of my '05 and that the dealer fixed it chop-chop... no charge.
Thanks Hopz, I always appreciate reading your advice & helpful comments on this forum.
The fuel pump flange, which can crack is a separate weakness in that area, I have the collar fitted over it, so that precaution is already taken.
The failure of the controller on top of the pump seems to be reasonably common, from what I have read.
It suffers from corrosion if water gets in, or is not monitored & kept clean.
I check it yearly, remove & clean it, as well as lubricating the seal, but was thinking of having a spare in case of failure.
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post #8 of 17 Old May 18th, 2017, 10:52 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

Quote:
Originally Posted by corrcullen View Post
Thanks Hopz, I always appreciate reading your advice & helpful comments on this forum.
The fuel pump flange, which can crack is a separate weakness in that area, I have the collar fitted over it, so that precaution is already taken.
The failure of the controller on top of the pump seems to be reasonably common, from what I have read.
It suffers from corrosion if water gets in, or is not monitored & kept clean.
I check it yearly, remove & clean it, as well as lubricating the seal, but was thinking of having a spare in case of failure.
Since you do a lot of long rides, I do think that getting a new FPC would be the wise choice, in particular to ease your mind. Otherwise, making a bypass connection in an emergency on the road is very easy to do. I happened to opt for wiring power up to the general area, but you can easily tap into the main fuel pump circuit for the power and connect that to the pump-side of the FPC, in the event of failure. That's why Larry keeps a length of conductors and several posi-tap connectors as part of his toolkit! BTW, if you do get a new FPC, do make sure that it's the "improved" one, with the black powder-coated finish. DO keep the old one handy, on the bike for spare, since even the improved one are also known to fail!

Pad. Gajajiva
Solon, OH, USA

2015 R1200RT (San Marino Blue Met.)
2014 R1200RT (Quartz Metallic Blue - Returned to BMW)
2007 R1200RT (Sold!)


Once Upon a Time........
1963 Norton Dominator 650 SS
1960 Triumph Bonneville (T120)
1960 Triumph Thunderbird (6T)
1952 Triumph Thunderbird (6T)
1932 Triumph 500
1952 BSA Goldstar
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post #9 of 17 Old May 18th, 2017, 9:53 pm
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Re: BMW Motorcycle Fuel Pump Bypass Cable

The 5 amp thing only applies to the first couple years R1200RTs.

The system was upped to 10 amps by, I think 2007.

Kent Christensen
Albuquerque
'12 R1200RT, '02 R1100S, '84 R80G/S
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post #10 of 17 Old May 19th, 2017, 9:44 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

Is the FPC something to concern yourself w/ on the waterboxer RTs? I'm reading references to older models so wonder about that.

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post #11 of 17 Old May 19th, 2017, 10:28 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

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Is the FPC something to concern yourself w/ on the waterboxer RTs? I'm reading references to older models so wonder about that.
Hi Noel, as far as I can see, there is nothing to concern yourself about wrt the Wetheads. Their track record seems impeccable (thus far)!
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post #12 of 17 Old May 19th, 2017, 10:57 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

Are you wiring around one of the connectors on top of the tank? The dealer is installing a new pump assembly on my 06 RT right now and it's under warranty. Are both of these connectors on top of the tank?

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post #13 of 17 Old May 19th, 2017, 12:42 pm
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Re: BMW Motorcycle Fuel Pump Bypass Cable

There is a nice illustrated FPC replacement guide here: R1200RT (all years) FPC Replacement Mini-Guide - BMWSportTouring Forums

The one in the pictures is newer black one, the early silver ones are the most troublesome. The FPC regulates fuel pressure by controlling the pump (I think it slows the pump by reducing the voltage, but it may just cycle the pump on and off). When the controller fails, the bypass is a temporary measure to provide constant power to the pump at the blue connector under the controller.

If the dealer replaces the fuel pump, they will transfer the FPC to the new pump, as the controller is a separate part and not included in the recall.
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2006 R1200RT
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post #14 of 17 Old May 19th, 2017, 1:57 pm
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Re: BMW Motorcycle Fuel Pump Bypass Cable

So, if I have this right, in order to bypass the FPC you wire the blue plug underneath into the black plug on top to make the pump work. Is this a common failure and would it be wise to carry a spare?

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post #15 of 17 Old May 20th, 2017, 7:02 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

I was on a trip last year with a few guys and one rider on a new-to-him '08 RT had an FPC failure. He had a new GS911 along but no jumper or spare FPC. Eighty mile tow back home, thanks AAA!

The rider with the failed FPC bought two pre-made harnesses that connect to SAE connector and gave me one for my '06. I bought two used eBay FPCs that bench-tested good so we both have a spare.

My take on it is if you do not wire in a harness that can be activated without removing plastic, carry a spare FPC. Swapping-out an FPC on the side of the road is a less than thirty minute job.

All that said, I carry both my spare FPC and the harness. I know the odds of needing both are very low, but I've got them in my travel kit.

Joe
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Last edited by Joe's '06 RT; May 20th, 2017 at 7:18 am.
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post #16 of 17 Old May 21st, 2017, 10:30 am
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Re: BMW Motorcycle Fuel Pump Bypass Cable

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Originally Posted by Joe's '06 RT View Post
I was on a trip last year with a few guys and one rider on a new-to-him '08 RT had an FPC failure. He had a new GS911 along but no jumper or spare FPC. Eighty mile tow back home, thanks AAA!

The rider with the failed FPC bought two pre-made harnesses that connect to SAE connector and gave me one for my '06. I bought two used eBay FPCs that bench-tested good so we both have a spare.

My take on it is if you do not wire in a harness that can be activated without removing plastic, carry a spare FPC. Swapping-out an FPC on the side of the road is a less than thirty minute job.

All that said, I carry both my spare FPC and the harness. I know the odds of needing both are very low, but I've got them in my travel kit.

Joe
In reference to your mention of the GS-911.............is that needed to diagnose an FPC failure? Or could you do it with a test light?

2005 K1200LT Ocean Blue
2003 K1200LTE Black
Totaled Oct 2, 2010
2006 Kawasaki Vulcan 2000
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post #17 of 17 Old May 22nd, 2017, 1:54 pm
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Re: BMW Motorcycle Fuel Pump Bypass Cable

I'll bet a simple circuit test light would work IF you knew a good starting point; if I remember correctly the GS911 indicated a fuel pump failure. Photo is the towing rig sent by AAA: modified Chevy Caprice wagon with shop-made trailer was awesome!

Joe
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