R1200 (2008) Oil Head: Fuel pump replacement
Posted: Mon 18 Aug, 2025 5:20 pm
After 210,000 km, my old 2008 R1200 GSA finally decided that enough was enough...
The fuel pump failed.
Diagnostic: Bypass fuel pump controller and power pump directly: NO GO.
I removed the fuel pump from the left side. After seeing what was inside, I removed the cover from the right side as well.
The problem was, of course, stale fuel. Ergo, my fault, not BMW. What a sticky mess on the bottom of the tank. And most likely in the pump, causing it to be stuck solid. It would not work directly connected to power.
I actually removed the tank from the bike and gave it a birthday. Clean and Armour-All top and bottom. ACF 50 all electronics. It was much easier to work with the tank off the bike.
For reference, I studied this very useful video from BestRest Products.
Watch and absorb it several times! Break the wrong piece of plastic and that'll be $800 thanks.
The fuel pump assembly from my R1200 GSA 2008 - plus Quantum Fuel Pump Kit reference numbers.
It was a fairly straight forward job. Removing the plastic from the GSA is always a drag!
Prior to installing the pump into the pump housing, I powered the pump unit with the bike system to ascertain that the system electronics were not at fault.
The included fuel pressure regulator was fitted. This is at the level of the left throttle body inside the frame. Relatively easy job.
There is a space in front of the airbox and above the ABS unit that will accomodate a fuel filter. This Ryco Z200 fuel filter is fitted into the fuel pump pressure hose cut in the aforementioned location. Mine is wrapped in protective foam and cable-tied stop movement.
Fuel Filter: Ryco Z200
I learnt my lesson years ago when I needed to replace the fuel level strip... Check for fuel leaks at the two (2) pump covers before putting everything back together... Don't ask how I know...
Handy to have a Sky Lifter to tip the back of the bike up high to test for fuel leaks with only half a tank of fuel.
I started the engine sans fuel pump controller to confirm all was OK.
Then fitted the fuel pump controller and started the engine to confirm that the controller was indeed working.
'Mechanic in a Bottle' (from the chainsaw section at Bunnings) was added to the tank to rejuvenate and stabilise any remaining dregs of old fuel... and hopefully clean out the gunk in the bottom of the tank (Thanks AP).
BestRest Products: https://bestrestproducts.com/
Mechanic in a Bottle: https://www.bunnings.com.au/120ml-mecha ... t_p0169259
Quantum Fuel Pump Kit: QFHFP382BRT3F2 (Do your own homework).
The fuel pump failed.
Diagnostic: Bypass fuel pump controller and power pump directly: NO GO.
I removed the fuel pump from the left side. After seeing what was inside, I removed the cover from the right side as well.
The problem was, of course, stale fuel. Ergo, my fault, not BMW. What a sticky mess on the bottom of the tank. And most likely in the pump, causing it to be stuck solid. It would not work directly connected to power.
I actually removed the tank from the bike and gave it a birthday. Clean and Armour-All top and bottom. ACF 50 all electronics. It was much easier to work with the tank off the bike.
For reference, I studied this very useful video from BestRest Products.
Watch and absorb it several times! Break the wrong piece of plastic and that'll be $800 thanks.
The fuel pump assembly from my R1200 GSA 2008 - plus Quantum Fuel Pump Kit reference numbers.
It was a fairly straight forward job. Removing the plastic from the GSA is always a drag!
Prior to installing the pump into the pump housing, I powered the pump unit with the bike system to ascertain that the system electronics were not at fault.
The included fuel pressure regulator was fitted. This is at the level of the left throttle body inside the frame. Relatively easy job.
There is a space in front of the airbox and above the ABS unit that will accomodate a fuel filter. This Ryco Z200 fuel filter is fitted into the fuel pump pressure hose cut in the aforementioned location. Mine is wrapped in protective foam and cable-tied stop movement.
Fuel Filter: Ryco Z200
I learnt my lesson years ago when I needed to replace the fuel level strip... Check for fuel leaks at the two (2) pump covers before putting everything back together... Don't ask how I know...
Handy to have a Sky Lifter to tip the back of the bike up high to test for fuel leaks with only half a tank of fuel.
I started the engine sans fuel pump controller to confirm all was OK.
Then fitted the fuel pump controller and started the engine to confirm that the controller was indeed working.
'Mechanic in a Bottle' (from the chainsaw section at Bunnings) was added to the tank to rejuvenate and stabilise any remaining dregs of old fuel... and hopefully clean out the gunk in the bottom of the tank (Thanks AP).
BestRest Products: https://bestrestproducts.com/
Mechanic in a Bottle: https://www.bunnings.com.au/120ml-mecha ... t_p0169259
Quantum Fuel Pump Kit: QFHFP382BRT3F2 (Do your own homework).