BMW R1200GS (K25) Replacing a faulty fuel level strip sensor.

Replacing a faulty fuel level strip sensor. In this video, I will show you how to replace a faulty fuel level sensor in a BMW R1200GS (K25) The video is quite a long, so I've included timeline bookmarks below so you can jump to a particular section. The video details removing the trim panels, fitting a new fuel tank level strip sensor and calibration using the HEX 911 diagnostic tool.
Timeline bookmarks
Introduction
6:11 Removing trim panels
11:10 Fuel tank removal
17:19 Examining the tank and removing the fuel pump
21:36 Removing the faulty fuel strip
24:01 Dry calibration of the new fuel strip using the HEX-911
29:50 Fitting the new strip level strip sensor
36:54 Refitting the fuel tank back on the bike
38:10 Refitting of trim panels
41:18 Summary and Inspection of the old fuel strip
I am not a mechanic and this video is only for entertainment purposes. If you rely on the information portrayed in this video, you assume the responsibility for the results.
Please feel free leave comments below on this subject or how I can improve my video’s
Thank you :-)

[@richarddepledge960]

Hi Just bought a 2012 triple black GS adventure 1200. With faulty sensor. Supposed to have been changed for me before delivery from dealer. Just thought I'd look on net and found your vid. Excellent piece of work. I might be doing this soon myself. Cheers for posting.

[@Jimmy2Teas]

Thanks Richard.

[@prototypecycle8977]

Thanks for the time it took to document the work. I'm in the States and my 2009 R1200GS Adv. was just serviced (by BMW recall) for faulty fuel pump(s). All went well. My riding partner with a 2008 version of the same bike picked his up yesterday and the mechanic tells him the fuel strip is bad. Note that it was working when he dropped it off. They want almost $300 to correct the problem. Now that I've watched your video, I'm confident that the scope of work is well within my capabilities. Thanks again. Stay safe.

[@Jimmy2Teas]

Great stuff, I'm glad it gave you the confidence to do it yourself. That's wanted to achieve with this tutorial. NB: If you're using the HEX 911, It's better to connect it to a laptop than a mobile phone like I did in the video. Good luck!

[@Priestonwheel]

Great video, thank! I really suggest replacing for the old floating type. The film is prone to fail on the worst moment

[@davewood7771]

Top job Jimmy. Subscribed.

[@wesbishop3790]

Thank you for the great video! Very well done!! I’m getting ready to replace mine for the 4th time in 13 years and 52k miles (2009 R1200RT). I’ve read everything I could find on the Internet concerning this issue and one common thing I have noticed is that most say that it fails right after they fill the tank with fuel. Makes me wonder if the pressure from the fuel pump spraying into the tank may have something to do with the breakdown. I also wonder if vibration from the road could be adversely affecting the strip. I read one owner put a bolt across the center of the fuel filler tube to keep the pump nozzle from going too far into the tank. I may try that as well. Blessings to you and yours!

[@CapCityDC]

Very helpful video, thanks!

[@iscadean6038]

Mine lasted eight years. CW BMW at Dorchester replaced it and 500 miles later it went again. CW have gone out of business, BMW UK don’t want to know yet replace FOC in the US. Thanks for this. I’ll have to do it myself. Oh, and there is a video on YT which shows a failed fuel strip being zapped with piezo clicker to reset it. Sparks and petrol though……

[@matt191275]

Excellent video buddy. Looks like mine needs doing so will give it a try after I get a GS911 😁

[@fabriziop7397]

Good I hope I don' t need to change it. It is a particular job !!

[@prototypecycle8977]

Just an update: Ordered a new fuel strip and was fully prepared to replace per your excellent instructions. I figured that I had nothing to lose by trying the "Zap" hack shown on several videos. Well it worked! I don't know how or why but no more yellow triangle. I have a new part in stock just waiting for the next inevitable failure. Thanks again.

[@Jimmy2Teas]

Great stuff. It will be interesting to know how long the “Zap” method works before the dreaded fault triangle appears again.

[@jeffroberts4893]

Hi, my fuel strip just went belly up. Same as Jimmy - out of gas with a 1/4 tank on the meter. Hasn't yet gone blank. Any update of the "zap" hack? Thanks!

[@prototypecycle8977]

My success with the "ZAP" method was short lived. Couple months at best. I replaced the strip and it does seem to be just a bit more accurate than the original 2009 item. Maybe it's just my imagination.

[@jeffroberts4893]

@@prototypecycle8977 Thanks! Maybe coincidence, but odd that this happened to me immediately after replacing the battery (myself because they wanted an hour labor) in the dealership parking lot.

[@prototypecycle8977]

@@jeffroberts4893 If you do decide to take on the fuel strip replacement pay attention to the "calibration" section in Jimmy's video. You'll need the GS-911 interface device to accomplish this step. I found that I can't be without my GS-911 and it has saved me well over the initial cost. I purchased mine @ the MOA rally in St. Paul, MN a few years back.

[@davidperry970]

Just got a 2010 GSA. It came with most of the service records and the fuel level strip has been replaced 4 times. And riding it home after buying it the gage stuck at 1/2 . So now I'm looking putting a float type sender with a inline calibration chip from Proebeemer they have all the Info.

[@jtbuilds1]

Great vid. Im tackling mine this weekend.

[@Jimmy2Teas]

Good luck!

[@sanderchaverri1582]

Really nice video I have the same problem in my case I have the guaranty from the firm I bought so it’s being fix but great video if I need in the future, as I heard they fail time to time & I got the book from a friend that now has a 2015 great video M8

[@Jimmy2Teas]

Thanks, let's hope you don't have to change it again!

[@p.musolf8310]

It seems that BMW is releasing a new/enhanced/more robust sensor in mid 2021. I got this info from my BMW dealer when I contacted them concerning my faulty sensor. Apperantly BMW recognized the issue.

[@Jimmy2Teas]

Brilliant news. About time too!

[@JeffinTD]

Didn’t they end up extending the warranty for these strips? Anyhoo, I’m on my 2nd and I run non-ethanol fuel (US).

[@p.musolf8310]

@@JeffinTD I don't think so. My bike is from 2009. To keep the warranty you have to run into a defect every 2 years. Products in EU are covered with 2 years of warranty.

[@JeffinTD]

I was able to find what they sent out here (USA). Basically they said they would replace failed fuel strips for 12 years from original sales date. I suppose it must have stemmed from some sort of action here. Anyway, excellent video. Enjoy the bike. Mine is also a 2009.

[@shandusa]

Great tutorial, thanks!

[@Jimmy2Teas]

Glad it was helpful!

[@2wheelsrbest327]

Thanks Jim great video. Yours is the 2nd one I have viewed the other one this job was being done by a professional mechanic and yours as convinced me even more that I will need a proper mechanic to do this on my 08 GS. I live in Eastbourne but I think I have some Yorkshire in me because for now I will just keep checking my speedo mileage 🤣. I love my GS but boy where do they get the price for their parts. Ted

[@Jimmy2Teas]

Thanks Ted for your kind words. Yes, BMW prices are very expensive, particularly when this part is likely to fail again. In my opinion BMW should offer this part at a heavily discounted rate.

[@2wheelsrbest327]

@@Jimmy2Teas Definitely Jim

[@shaun2049]

We’ll done good video

[@GD-sq2vj]

very wel done. thank you.

[@Jimmy2Teas]

Thanks for watching!

[@AzryShamsury]

Good video i have the same problem on my bike r1200gs ...i i need to replace the fuel stip like yours...

[@Jimmy2Teas]

Thanks. I'm glad the video helps you. Good luck!

[@cbrboy76]

Just bought a 1200 adventure, the faff to remove the tank, my old R1150GS had 1 bolt and the fuel lines to remove and it slid off. Why do bmw insist on complicating things.

[@steveneastwood]

Video looks great - will give it s go ! But have one question before starting and following your instruction - does the tank need to be emptied ? Or can the petrol remain in the tank while using the zapper ? Thanks heaps

[@Jimmy2Teas]

Zapper......I didn't use one in my video. I definitely wouldn't recommend zapping any fuel tank!

[@zanata3186]

Eu coloquei uma de potenciômetro, nunca mais incomodou.

[@Jimmy2Teas]

Hmmm....Installing potentiometer is one option, if you don't want to use the fuel gauge. What resistance value did you use?

[@martychin9496]

It's expesive as hell from the dealer, if they install it, its warrantied for 3 years parts and labor. Some last a long time, others crap out in a year, warrant is not a bad idea.

[@the14ball]

So, you calibrate it using the GS911 outside the tank when it’s dry. Then it’s okay to disconnect it, & reconnect it later and it’s okay & the calibration stays put? I thought it may have to stay connected. But I’m thinking that all the calibration does is mate it to the CPU.

[@Jimmy2Teas]

Yes, calibrate it dry, otherwise you will get an offset and not a true reading of the tank level. The ECU needs to know what the sensor value is when dry. This zero value is stored within the ECU and then compared with sensor’s changing value as the fuel level rises and falls. This difference is calculated to give the actual fuel level. Hope my explanation helps you.

[@the14ball]

@@Jimmy2Teas Yes. Thank you.

[@neilforker84]

BMW has historically and arrogantly refused to admit their design/philosophical mistakes. Integral ABS with common failures. Come on! Fuel strip that is almost guaranteed to fail. Really!?! Rear diff issues? And although they are completely aware of the problems they won't do a thing about it. I recently let the local (USA) dealer flush the brake system. $420 US. YOWSA! It's complicated, but I'm doing it myself next time. My fuel pump was replaced under a recall 10 years into ownership. Yay! But now, five years later, the fuel strip has failed. Zapping has not cured it. $285 labor quote. No quote for the part. Didn't ask for that, but I told them if they quoted me $285 for the part and labor I'd let them do it. Crickets. Good old BMW. All about customer [dis]service

[@Jimmy2Teas]

Totally agree with Neil. I also think these more modern BMW’s are far more complicated than they need to be. (I’m old school- keep it simple) The amount of kit and special tools needed to diagnose, service or repair these machines puts it out of reach most people to carry their own repairs. That’s my I’m keeping my old late 90’s R850R classic.

[@peter6782]

god kill me it was like having teeth pulled watching this !!!!! take about fiddling about.