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1999 BMW K1200LT
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12 Posts
Discussion Starter · #1 · (Edited)
I've always wanted a BMW motorcycle, and I finally picked one up yesterday. It's a 1999 K1200LT with 105k miles. It had been sitting the last couple of years, but the owner would start it every couple of weeks. It finally reached a point where it would turn over, but not fire. He traced it to -at least- bad wiring in the tank for the fuel pump. He was physically unable to continue work on the bike (has a shoulder that needs surgery) and he decided to sell it cheap, in hopes that it would get fixed, rather than sending it to a junkyard.

Here is the fuel pump assembly removed from the tank:
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I've been reading up in the forum here on the common fuel pump assembly issues, and it seems this one has them all. The wiring in the tank was horribly deteriorated.
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And the contacts at the flange/bulkhead passthrough are broken off:
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I bench-tested the pump and it is not running at all - it makes no attempt to run when power is applied.

So, I have ordered a new pump and filter. Based on other posts here, I decided on this one https://www.amazon.com/dp/B07RSCVX1X . It includes the strainer and new fuel filter, too, which certainly need to be changed, based on the condition inside the tank.

I also ordered the nylon in-tank fuel line ( Flexible In-Tank Fuel Hose Kit ) and fuel pump assembly "tune-up" kit ( New Fuel Pump ) from beemerboneyard. The previous owner already had the appropriate in-tank repair wires.

So, now I need to figure out how to repair the wire contacts at the assembly flange ("bulkhead). There may be enough left where I could solder terminals onto what is left. Or, I could try and melt new contacts through that plastic. BUT, I was intrigued by these: Bulkhead Stud, 6mm Delron/Viton, SS (BHS-6MSS): Bulkhead Connectors . Fitting 2 of them through the flange would seem to do the trick, and then I could re-use the bike side wires+connector. Has anyone tried those?
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Thanks for any advice! I already found the .pdf of the service manual online, so that will be handy to have.

Oh, and anyone have a recommendation for an adapter to use to lift the bike on a 2-post lift (I've got one in the shop garage)? It might be helpful for certain maintenance/repair tasks.

Here's a pic of the bike (it came pre-disassembled)...
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Where are you located? Some members might be close enough to be a good resource for you.
 

Wrencher Extraordinaire
2005 K1200LT
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15,456 Posts
Search back a few months as there was a guy that worked out a feed through solution but your choice of the Delron/ Viton studs looks very promising.
 

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1999 BMW K1200LT
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12 Posts
Discussion Starter · #6 ·
I grew up in Elmhurst (I stop in and visit old neighbors on the way), and then we are typically in McHenry (the city itself) or out in Woodstock. I'm down in Crystal Lake every now and again, too. Which is Kirk's shop?

I usually try and find a way to make a visit to Route14 auto parts, too - just in case. Never know what you'll find out in the yard!
 

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I grew up in Elmhurst (I stop in and visit old neighbors on the way), and then we are typically in McHenry (the city itself) or out in Woodstock. I'm down in Crystal Lake every now and again, too. Which is Kirk's shop?

I usually try and find a way to make a visit to Route14 auto parts, too - just in case. Never know what you'll find out in the yard!
I know those places, I live in Elgin.
Kirk works out of his garage, not far from Crystal Lake brewing.
Here is his website if you want to contact him: Kirk's Motorrad Shop (kirksmotorrad.com)
Or linked through our local club: Home - Northern Illinois BMW Riders
 

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1999 BMW K1200LT
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12 Posts
Discussion Starter · #8 · (Edited)
Search back a few months as there was a guy that worked out a feed through solution but your choice of the Delron/ Viton studs looks very promising.
I received the studs yesterday and looked them over. Unfortunately, I think they're meant for a thicker, fuel-cell-type of wall for the pass-through, rather than the thinner gauge metal of the fuel pump assembly flange. It's not a fault of the vendor or anything, I just couldn't get a feel for how to use them and if they would work without seeing them and sizing them up against the fuel pump assembly.

I'm back to trying to figure out a way to use what's left of the contacts on the original connector to restore the power connections to the pump.
 

Wrencher Extraordinaire
2005 K1200LT
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15,456 Posts
Any way to shave down the step that holds the O-ring to make it thinner?
 
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1999 BMW K1200LT
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12 Posts
Discussion Starter · #10 ·
@jzeiler , let me post a picture of the post assembly. Looking at it gave me some more ideas, though. I may have to souce some fine, long, stainless M2, 3 or 4 screws, nuts, and washers to make it work...

BTW, on that other connector idea thread, did you think you meant this one?
 

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2003 BMW K1200 LT (88K on 2020/08/13)
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283 Posts

Registered
1999 BMW K1200LT
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12 Posts
Discussion Starter · #14 ·
Before we went out of town this weekend to visit family in IL, I decided to let the fuel pump assembly soak in Evaporust. After taking it out and cleaning it today, these are the results - not bad!
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Remember, this was the before picture (below):
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I turned the assembly around and am letting the other half soak for a few days until I can get some more time to look a the wiring. The contacts are completely gone (as seen from the inside of the tank). I'm thinking to melt something else through there, instead, to use as a contact, and then sealing it with that Permatex fuel gasket sealant.
 
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