I Smell Gas.

Not a great feeling when you’re a couple hundred miles from home.

BMW Fuel Line Repair Kit
Image courtesy Beemer Boneyard.

Unfortunately I had a pretty good idea where the odor originated from. My 2005 BMW R1200GS has a pair of quick disconnect fittings on the fuel supply lines. This is common on most Oilheads. These are a wonderful thing when removing the fuel tank or performing other routine maintenance. But they can be a real problem if they break and start pissing gasoline down your pants leg.

And break they do.

The fittings are plastic and can crack or deteriorate over time. BMW sourced the couplings from a company in Minnesota. Too bad they didn’t opt for the brass version!

But now you can correct the mistake made at the factory. The whole job took me about an hour. If it weren’t for the OEM hose clamps it would only take 15 minutes!

RH Fuel PickupBeemer Boneyard offers a kit with the brass versions of the same quick disconnects. These are made by the very same company that supplies the plastic ones to BMW. For about $80 the kit includes the two fittings, thread sealant and “real” clamps to replace the %|*~§@≠ crimped-on clamps. I pretty much destroyed the old clamps to get them off. And cut my finger. And cussed a lot.

My GS is a 2005 so it uses the early style kit with two 90° fittings. Access to both is pretty easy once the plastic shrouds are removed. The LH side has a round cover that snaps off to reveal the fuel pump controller and electrical connections. Pry back the tiny tangs on each connection and unplug them before attacking the crimped fuel hose clamps. To remove the female fittings I snapped off the lock tabs and used a deep 19mm socket. If you use a wrench be careful not to exert any more side loading that necessary!

After: note the chrome fitting- I got a little carried away with the thread sealer.

Two words of caution before tackling this job:

Do empty the tank first- or close to it. On my GS the flange on the right (above) is on the side of the tank.

Do NOT overtighten the threaded fittings. The female side of the connectors screw into  plastic flanges that are notorious for cracking. In fact, it’s such a common mistake Beemer Boneyard sells a special little clamp for making that repair too!

Once the clamps were tight I turned the key a few times to prime the fuel pump and check for leaks. Everything looked good so I fired it up. After letting it run a while I buttoned everything up and put the plastic back on.

Snif sniff….  I don’t smell a thing!