Boy... when it rains it pours. I had one of my Metzeler Z6 tires suffer an internal failure (the post is in the ride well forum) a couple of days ago and then today I smelled fuel as I was riding and I noticed streaks of dried fuel on the plastic on the left side of the fairing. When I arrived home today, I notices a few drips coming from the lower leading edge of the left side fairing. Suspecting that if I'm having a fuel leak then someone else has had it, I ran a quick search of this forum and came up with a handful of threads highlighting fuel leaks from the fuel pump around the high pressure output fitting. Suspecting this might be the problem I removed the left hand side plastic and sure enough, the plastic around the fuel pump output fitting is cracked and leaking.
There are two ways to fix this problem; replace the fuel pump or fix the crack. When I called my local BMW dealer and asked about prices... the OVER $500 cost for the pump and gaskets secured my decision... I'm going to try and fix the problem. One thing that disappointed me is that my BMW dealer (where I purchased my 2005 R1200RT) wouldn't even give me a 10% discount on the parts. The parts guy was well aware of the cracking problem, he said he sold two fuel pumps last week for the exact same issue. When I told him that I was going to go ahead and try to repair the problem, he said that JB Weld turns to mush around fuel (something I know to be false since I checked JB Weld's site and their product is impervious to fuel). So much for my friendly neighborhood BMW Motorcycle shop
After removing the left hand side plastic and the output fitting, I sanded all of the plastic in the area I was repairing, cleaned it thoroughly with alcohol, mixed the JB Weld and started the repair. The pictures of the repair and prep work are below.
I'm not yet sure if the repair will hold since I need to let the JB Weld cure. Others on this board who have done this repair reported that it fixed the leak. I'm keeping my finger's crossed. If it leaks after this... then it's off to the web to order the part from someplace that is willing to discount the darn thing.
I must admit to being a bit disappointed. This is the first systemic problem I've had with my BMW and I was hoping to avoid all of the problems that crop up on this board; fuel strip, final drive, fuel pump... oh well... I guess one out of three isn't bad since some folks suffer from all three problems.
Anyway... here's the pictures. I'll let everyone know tomorrow if this repair works.