R1200GS/A Hidden Filter bypass

Moonmanzn · Apr 29, 2020

Evening, found out my hidden filter in my fuel filter housing had collapsed so I bypassed it.

You will need the following

Mahle Filter KL145 from an R1150
7mm Drill bit
8mm Drill bit
Drill
3 x 10 - 16mm jubilee clamps
8mm ID Fuel hose x 30cm ish

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Moonmanzn · Apr 29, 2020

Remove your pump from the tank
Remove the fuel pump housing assembly and all connectors

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Moonmanzn · Apr 29, 2020

Take out the top Quick disconnect fitment with a 19 spanner

You will now need a 8mm drill bit.

Measure the drill bit so that 63mm is protruding to use as a stop once desired depth is reached.

Slowly and carefully drill through the hole left by the quick disconnect, use a slow speed and gentle pressure.

You will feel the drill bit catch the plastic of the inner filter. Slowly drill, stopping and checking every turn or two. After a few revolutions you will feel the drill slide through the inner filter housing.

!!!Be very careful as too much pressure will mean you drill through the outer white shroud and your fuel assembly will be ruined!!!

Once through the inner plastic cover, you should be able to see light passing through the outer white surround.

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Moonmanzn · Apr 29, 2020

The first hole will be enough for full flow and bypassing the filter.

If you want to be 100% sure you have max flow you can use a 6mm drill bit in the bottom of the housing fuel in spigot.

Drilling slowly and at the correct angle, within 30mm you will make contact with the bottom of the hidden filter housing.

Carefully drill through, reverse the drill and pull the bit out.

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Moonmanzn · Apr 29, 2020

Once both holes/hole are drilled

Use fresh fuel in a syringe to flush the housing of plastic shrapnel.

I rigged the pump to a 12v battery and placed the pump in fresh fuel and used the pumps forces to clean the housing out.

Be careful with sparks and fuel

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Moonmanzn · Apr 29, 2020

Once complete with the flush.

Wrap the quick disconnect threads in plumbers teflon tape and reinsert into top of housing, 19mm to tighten it up snug.

Insert the fuel pump assembly into tank, ensure you soak the gasket in fuel and place it onto the tank hole and not around the assembly.

Tighten down with the locking ring.

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Moonmanzn · Apr 29, 2020

Disconnect the male quick connect from the hose as pictured.

Insert the output end of the new filter into the hose that leads to the injectors and tighten up with a jubilee.

Then connect a short 10/15/20cm bit of fuel hose to the IN side of the filter and tighten up with a jubilee.

Attach the male quick connect and arrange the filter as you see fit.

I then disconnected the fuel lines from the injectors and turned over the motor allowing the lines to purge into a bucket before reinstalling and firing her up.

Cheers

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p.joe · Apr 29, 2020

RESULT... Well done

I think a lot of fellow members felt they were on this adventure with you and feel your relief. I have to commend your tenacity..... Imagine what the cost would have been had a dealer had to do all this work.

Regards P.J.

GORILA · Apr 30, 2020

Superb description of how you fitted the filter! Thanks for taking the time to do this.

Slipperyeel · Apr 30, 2020

As per all the other comments. I too have been following your posts on this with interest and feel your satisfaction at sorting it. Well done

I'm definitely noting your story - and the solution. But I have a question. I'm unclear why you didn't just by a new OEM filter? I've now looked at the fiche and it looks like the entire pump/filter assembly is sold as one unit, for about £350

. Have I got that right?!

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Moonmanzn · Apr 30, 2020

Slipperyeel said:
As per all the other comments. I too have been following your posts on this with interest and feel your satisfaction at sorting it. Well done

I'm definitely noting your story - and the solution. But I have a question. I'm unclear why you didn't just by a new OEM filter? I've now looked at the fiche and it looks like the entire pump/filter assembly is sold as one unit, for about £350 . Have I got that right?!

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I was coming up with 450£ for the assembly.

They should normally flush out but mine actually collapsed I think. Only found 2 others with that issue so super rare I would say.

But now I have a replaceable filter that's extra 12£ and 10min come service time.

BMW has license to print money on some "lifetime" things on bikes/cars

Ian J Hartley · Apr 30, 2020

Excellent write up, with embedded pictures. Well done.

However, I would not use jubilee clips, I would use hose clips instead, they give a better uniform clamping force.

Ian :thumb2

Moonmanzn · Apr 30, 2020

Ian J Hartley said:
Excellent write up, with embedded pictures. Well done.

However, I would not use jubilee clips, I would use hose clips instead, they give a better uniform clamping force.

Ian

Yeah have some on order coming Saturday but no open shops had size I needed

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Slipperyeel · Apr 30, 2020

Moonmanzn said:
I was coming up with 450£ for the assembly.

They should normally flush out but mine actually collapsed I think. Only found 2 others with that issue so super rare I would say.

But now I have a replaceable filter that's extra 12£ and 10min come service time.

BMW has license to print money on some "lifetime" things on bikes/cars

Blimey. My £350 was an approximation. Not bad just to change the filter

I'm glad it's a rare fault issue!

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Pukmeister · May 1, 2020

What symptoms were you having that made you suspect the collapsed filter ??

Moonmanzn · May 1, 2020

Pukmeister said:
What symptoms were you having that made you suspect the collapsed filter ??

Just bike was fuel starved at higher rpm. Try above 80 and slowly creeped up like I was riding in massive headwind or bike was governed.

Santa-2512 · May 1, 2020

Moonmanzn said:
Just bike was fuel starved at higher rpm. Try above 80 and slowly creeped up like I was riding in massive headwind or bike was governed.

If it's the same filter / housing unit used in single cam, could the same problem manifest itself in those models ?

My 06 hex had exactly the same symptoms

Moonmanzn · May 1, 2020

Santa-2512 said:
If it's the same filter / housing unit used in single cam, could the same problem manifest itself in those models ?

My 06 hex had exactly the same symptoms

Yeah housing is the same from the first one onwards, they changed from fuel strip to float but the hidden filter never changed.

My drill bit came out of the housing packed with like old superglue or silicone.

Rode an hour today and she is running lovely

Pukmeister · May 1, 2020

Thanks for the reply, my '08 Hexhead has had intermittent issues for years, only occasionally running silky smooth but mostly a bit rough and strangled. I never knew about this hidden pump housing filter but now I am doubting mine is intact so might get the drill out.

Stan H · May 1, 2020

Awesome result and write up, your persistence is amazing :bow

Just came across a pretty decent end to end vid on how to backflush the hidden filter 'as another option' (lots of useful tips around assembly and disassembly... etc etc). Makes you wonder how many GS's are rolling around without pulling with all their ponies at the top end :blast

Skip ahead to 29:30 to see the start of the hidden filter backflush process.

R1200GS/A Hidden Filter bypass

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