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Can a cracked Fuel Pump Assembly be repaired? HP2

visian

look out!!!
Bike is an HP2 Enduro, but has the same fuel pump assembly parts as an R1200 GS.

Referring to Part #1 below (BMW part # 16 14 7 690 281) yesterday, in the middle of the woods in Tennessee I started smelling gas and discovered that the threaded hole that holds the female and male quick disconnect valve is cracked, and one of the cracks was squirting fuel.

After removing the male quick disconnect and unscrewing the female receiver, there was white goop that looked like the remains of some teflon tape.

I believe that when installing the aftermarket HPN fuel tank, the previous owner (or the dealer) over-tightened the female receiver and cracked the fuel pump assembly. I've owned the bike for about a year and have ridden it about 6K miles.

Has anyone ever seen this, and if so, know what the likelihood of repairing this $550 part is?

Thanks!

Ian


B0004829.png
 
Steve - thanks.

In your picture, mine has small cracks in the threaded hole immediately to the right of the red circle... although I think the answer may still be the same....

crack.jpg
 
If ou haven't, remove the assembly and let it air dry. Hold it up to light and look from below and see if you see light. If so, that's roughly the same as mine. If not - it's probably the threaded part the elbow plugs into. Either way - bad news.
 
Those things can be fixed. Beemer Boneyard sells a clamp to stop them from cracking around the flange or area where the disconnect enters.
They usually fix with epoxy and there is great and continuing controversy as to which epoxy is best.
Usually, if they are not too far gone, the fix works good for some time.
There have to be 1000 posts here and elsewhere about it.
dc
 
Hey all... thank you very much for the links. I just suck at searching forums.

The cracks I have are of the radial type as shown in DBrick's ADVrider link. I am hoping that I can repair and then go with the metal replacement QD connector.

Interestingly, the part has gone from ~ $300 to nearly $550 in the course of a year. :scratch

Ian
 
FYI, here is exactly the problem I am having... and from what I am reading, this is a design flaw, an inappropriate use of tapered threads.

Crack-seal-2.jpg


Crack-seal.jpg
 
venting: you know, I am really getting tired of the increasingly cheaper crap coming from BMW at ever-increasing prices. And don't even get me started about the raping we're taking over parts..

This just isn't right.
 
Using a tapered thread isn't by itself a problem. We seal natural gas and many other flammable items with tapered thread stuff.
The real issue is the use of a wrong material- unsupported plastic- for that part. Were the female fitting metal it would not split- that's why the clamp and the new part are improvements. Plastics deform with continued pressure and only appropriate engineered plastics (like items reinforced with fiberglass or CF fiber in the mix) will permanently resist the spreading force of a taper thread especially if over tightened. Its very easy to over tighten plastic, especially if using a thread sealer that also will act as a lubricant when tightening the part.
All in all a pretty stupid design that was apparently farmed out by BMW. There is very little that is actually well done on the current fuel system design with the exception of the pump itself which seems as reliable as any other. Pretty much every other part is known to be susceptible to early failure from the flange itself to the quick disconnects to the fpc to......well, you get the idea...
But hey, the tanks at least don't blow up like Ducati's balloons.....
 
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