Replacing The Fuel Pump In Your Bmw R1200rt: A Step-By-Step Guide

If you're looking to replace the fuel pump on your BMW 2005 R1200RT, you're likely experiencing issues with your fuel pump or fuel pump controller. It's important to identify which component is faulty before attempting any repairs or replacements. Common signs of a faulty fuel pump include a vehicle that won't start or sudden engine stalling. On the other hand, a faulty fuel pump controller may exhibit similar symptoms, such as a lack of spark to the plugs and no noise from the fuel pump when the key is turned.

Before replacing any parts, it's recommended to perform some basic diagnostics to narrow down the issue. This can include checking voltage readings, performing a fuel pump bypass, or seeking guidance from a BMW forum or a trusted mechanic.

Removing the top retaining lock ring

To remove the top retaining lock ring of your BMW 2005 R1200RT's fuel pump, you will need to first access the fuel pump assembly. This is located inside the fuel tank, so you will need to remove the fuel tank from the bike. Once you have the fuel tank removed, you can access the fuel pump assembly.

The next step is to remove the fuel pump assembly from the fuel tank. To do this, you will need to remove the top retaining lock ring, which secures the assembly in place. The lock ring is typically made of metal and can be unscrewed using a wrench or a pair of pliers. Make sure you have a firm grip on the lock ring and turn it counter-clockwise to unscrew it.

It is important to note that the fuel pump assembly is under pressure, so you will need to relieve the pressure before removing the lock ring completely. To do this, you can carefully press down on the fuel pump assembly while turning the lock ring. This will release some of the pressure and allow you to remove the lock ring more easily.

Once the lock ring is removed, you can lift the fuel pump assembly out of the fuel tank. Be careful when handling the assembly, as it contains sensitive components, including the fuel pump itself.

When reinstalling the new fuel pump assembly, make sure to follow the correct sequence. The bottom white retaining ring should be installed first, followed by the rubber gasket, the fuel pump, and then the top metal retaining lock ring. This will ensure that the assembly is secure and sealed properly.

Additionally, it is recommended to use a suitable sealant or gasket maker when reinstalling the fuel pump assembly to prevent fuel leaks. This will help ensure the safety and proper functioning of your BMW 2005 R1200RT's fuel system.

Installing the bottom retaining ring

To install the bottom retaining ring, you will need to place the white plastic ring at the bottom of the assembly. This is followed by the rubber gasket, the pump, and finally, the top metal retaining lock ring.

Firstly, ensure you have the correct part. The bottom retaining ring is made of white plastic and is crucial in keeping the assembly secure. Check the part for any defects or cracks, as this will compromise the integrity of the installation.

Next, carefully place the bottom retaining ring into position. It is important to handle the part with care to avoid any damage during installation. Ensure the ring is securely fitted and aligned correctly.

Once the bottom retaining ring is in place, you can proceed to install the rubber gasket. The gasket will sit on top of the bottom retaining ring and provide a seal for the assembly. Again, carefully place the gasket and ensure it is properly seated.

With the gasket in place, you can now install the fuel pump. This is a crucial component, so handle it with care and ensure it is securely connected to the other parts of the assembly.

Finally, you can install the top metal retaining lock ring. This will secure the entire assembly in place. Make sure the lock ring is properly engaged and fastened securely.

By following these steps, you will have successfully installed the bottom retaining ring and completed a crucial step in replacing the fuel pump on your BMW 2005 R1200RT.

Draining the fuel from the tank

To drain the fuel from the tank of your 2005 BMW R1200RT, you will need to locate the fuel pump and identify the fuel lines. The fuel pump is located inside the fuel tank, and the fuel lines are the hoses that connect the fuel pump to the engine. Once you have located these components, you can proceed with the following steps:

First, place a suitable container under the fuel tank to collect the drained fuel. Make sure you use a container that is specifically designed for storing fuel and ensure that you are in a well-ventilated area.

Next, locate the fuel line quick-disconnect fittings. These are the fittings that allow you to easily disconnect the fuel lines from the fuel pump without needing to cut or modify the hoses. Disconnect the fuel lines from the fuel pump by pressing the quick-disconnect fittings and pulling the hoses away from the pump. Be prepared for some fuel to spill out of the lines, so have rags or paper towels ready to absorb any spills.

Once the fuel lines are disconnected, attach a fuel siphon to the fuel pump. A fuel siphon is a device that allows you to transfer fuel from one container to another. You can purchase a fuel siphon from most auto parts stores. Follow the manufacturer's instructions to properly attach the siphon to the fuel pump.

With the siphon in place, you can now activate the fuel pump to start draining the fuel from the tank. Be careful to monitor the fuel level in the container as it fills up, and replace the container as necessary to avoid overfilling.

Finally, once the fuel tank is empty, remove the fuel siphon and reconnect the fuel lines to the fuel pump. Make sure the connections are secure before starting the engine.

It is important to note that working with fuel can be dangerous, so ensure you take the necessary safety precautions. Always wear protective gear, such as gloves and eye protection, and avoid any open flames or sparks during the process.

Checking for low voltage on the fuel pump control unit

To check for low voltage on the fuel pump control unit, follow these steps:

• Locate the fuel pump control unit, which is mounted on top of the fuel pump/filter assembly.
• Use a multimeter to measure the voltage at the fuel pump control unit. Ensure that the engine is being cranked or turned over during the measurement.
• If the voltage is below the specified level (typically around 12V), there may be an issue with the power supply to the fuel pump.
• Check the wiring diagram to identify the power supply path to the fuel pump. In some BMW models, the power supply to the fuel pump comes directly from the ECU.
• Verify that the earth connection is good by checking the battery for a strong ground.
• If the voltage is still low, the fuel pump relay may be faulty. The early relays were silver, while the later modified ones are black. Consider replacing the relay or applying 12V directly to the pump to confirm if it is the issue.
• If the problem persists, there could be a potential issue with the main ECU. Consult a professional mechanic or a BMW dealer for further diagnosis and repair.

Replacing the fuel pump controller

To replace the fuel pump controller on a BMW 2005 R1200RT, you will need to purchase a fuel pump bypass cable. This cable will allow you to bypass the faulty controller and get your motorcycle running again.

Step 1: Purchase a Fuel Pump Bypass Cable

You can purchase a fuel pump bypass cable from various retailers, including BurnsMoto. This cable will allow you to connect the accessory port directly to the battery, bypassing the fuel pump controller.

Step 2: Remove the Left Side Gas Tank Cover

Start by removing the left side gas tank cover on your BMW 2005 R1200RT. This will give you access to the fuel pump and fuel pump controller.

Step 3: Remove the Black Fuel Pump Cover

Once the left side gas tank cover is removed, you will see the black fuel pump cover. Remove this cover to expose the fuel pump and controller.

Step 4: Disconnect Power to the Fuel Pump Controller

Using a small flat screwdriver, carefully pry open the retaining clip that connects power to the fuel pump controller. This will disconnect the power supply to the controller.

Step 5: Remove the Fuel Pump Controller

The fuel pump controller is held in place by screws. Use a Torx ratchet socket, size T-20, to remove the screws. For the rear screw, it may be easier to use a Torx T-20 screwdriver. Gently pry up the fuel pump controller to remove it from the fuel pump.

Step 6: Connect the Bypass Cable

Look inside the fuel pump connector and you will see a BLUE connector. Squeeze the tabs on this connector with a small screwdriver to make it easier to remove. Then, take your fuel bypass pump cable and align its connector with the top of the fuel pump connector. Ensure they are properly aligned before connecting.

Step 7: Connect the Cable to the Accessory Socket

Insert the Powerlet connector of the bypass cable into your accessory socket. Make sure that your accessory socket is rated at 10 amps, as the fuel pump draws 7 amps.

Step 8: Start the Motorcycle and Tuck the Cable

With the bypass cable connected, start your BMW 2005 R1200RT. The motorcycle should now be running, as the faulty fuel pump controller has been bypassed. Tuck the bypass cable under the side covers to keep it out of the way.

Note: This procedure is a temporary fix and you may still need to purchase a new fuel pump controller from BMW to permanently resolve the issue.

Frequently asked questions