F650GS Fuel Tank FAQ

compiled & edited by Kristian #562
Please read the Disclaimer before attempting any work in this FAQ.
Last Updated: 21 October 2006, by Winter #1935

• General questions
  • My Gas Tank is Split/is Leaking. Is this Common?
  • Repairing a Leaking Gas Tank
  • Why does the American Gas Tank contain less Fuel than the European Model?
  • What is the charcoal filter in the American tank for?
  • What is the average Gas Mileage/Tank Range for the GS/Dakar
  • When does the Low Fuel Light come on
  • No Petcock? Emptying the GS Gas Tank?
  • Fuel Light Not Working?
  • Fuel Light Coming On Early?
  • Does the OEM Tank have an Overflow?
  • Should I refuel on the Sidestand or Centerstand?
  • Gas cap failure?
  • Is there an aftermarket gas cap?
  • Colour Fade on Fuel Tank

For other related FAQs:

• For Aftermarket Tanks for the GS/Dakar see Aftermarket Fuel Tank FAQ GS
• For Classic Tank or Mileage Questions see Gas Tank Removal-Replacement or Poor Mileage FAQ
• Also see the Fuel Injection FAQ

Recalls and Service Bulletins:

• Please see the Service Bulletins FAQ
• 19-Sep-2000, 16-002-00 (036)r, Recall 00V-267: Fuel Tank Replacement
• Aug-2006, 16-001-06 (039), Check of fuel-pump return port
• (CS Only) May-2004, 16-002-04 (009), Advance Notice of Recall: Possible Fuel Pump Flange Leak
• (CS Only) May-2004, 16-002-04 (009), Recall 04V-236 - Installation of fuel pump flange cap

• Well there is a Recall Notice out on EARLY Tanks, but some problems even with '02's have been reported, which are NOT part of the recall. See the list of Service Bulletins at the top of this FAQ for the Recall notice.
• Look at the cap under the seat hasn't come loose and fuel isn't pooling there as the bike bounces around. Just need to tighten it
• A recall has been issued for the F650CS models in May 2004 related to fuel leaks. If you do experience a leak on any bike similar to those leaks listed here, first contact your dealer - as another recall may have been issued. If they do not wish to fix the problem, contact your national transport safety organisation (in the US try the http://www.safecar.gov).
• Feedback on Split Tanks
  • There was a recall for faulty fuel tanks in the US for some of the early GS models. Mine, with a July 00 build date, was one of them. The problem had to due with potential leaks due to thin wall in the tank somewhere. Mine never leaked and I never heard of any that actually did. Suffered similar hairline cracks in the fuel pump assembly cap just 2 weeks ago. Dealer assured me this was a different problem than the initial gas tank recall. Had to epoxy the cap until dealer was able to get the replacement part. All covered under warranty, but fuel spilling on hot exhaust definitely an attention getter! Here is a photo of the cracks that developed in the fuel pump assembly cap. They seem to follow a diagonal line up the cap, so I believe it may be from a molding problem. I should still have photos of the cracks that developed in my cap just after the 6K service. Interesting to see this problem on an '02GS, I previously figured the problem was due to a bad batch of caps in the early production. Thanks to Mike#976 for the Photo.
  • Like Mike #976, I also had a hairline crack in the fuel pump/filter assembly "cap" on top of the tank. My '01 GS had about 4200 miles on it, and it was about 9 months old so the fuel pump/filter assembly was replaced under warranty. (Bike is an 02-2001 build) Since I've had no real surge/stall issues I was worried that the replacement fuel pump would be "below spec" (see the FAQ page) and would possibly cause problems. But to my surprise, it ran fine and the already great mileage (~61 mpg commuting to work) improved a bit, ~65 mpg. Barrett ABQ.
  • Having just re-fuelled at a service station, to my surprise, a "fuel river" developed from under my seat. Having removed my seat, upon closer inspection, I discovered a hairline-crack on the black carbon? insert on top of the fuel tank. I will be contacting my dealer on Monday morning for a fuel tank replacement. Have other 2001 F650GS owners in South Africa had this problem? Joe Ruhfus, Advrider
  • All the US tanks were replaced almost two years ago, right after the new 650 was introduced here in the States. My delivery was delayed 4 weeks while new tanks were shipped and installed on all the dealer's bikes, and those of customers who had already taken delivery. The replacement tanks have a sticker affixed to the top that shows the replacement date. Jinx, Advrider.
  • Smell gas? I did, and removing the seat from my '01 GS/D revealed a leak around a hose fitting on top of the tank -- gas was pooling in a depression around the pump fittings. I loosened the clamp, pushed the hose down further, and retightened it and the one next to it. That fuel pump puts out high pressure for the injection system. It's easy to test for leaks by simply removing the seat and turning key on for a few seconds. I'll do this regularly now to prevent any unplanned BBQ's. Larry#694.
  • 650 GS Leaky fuel filler/tank. Apologies if this subject has been covered already on this board, but obliged if anyone can help. I have a year 2000 650GS which has a tendency to leak fuel: are there any known problems /solutions? As far as I can see the fuel leaks from somewhere under the plastic panel, rather than from the filler cap and then runs down over the dimpled plastic piece onto the chain guard. When I fill the bike I do tend to brim it, but I fill it on the centre stand rather than side stand so I don't think that is the issue. Maybe it is but....I filled up yesterday and have done maybe 20 miles and it is still possible to slosh fuel out by jerking the bike over to the right. Is there a breather pipe or similar in there? I haven't had time to dissemble the parts yet so any ideas anyone? Dublin Nick
  • 650 GS Leaky fuel filler/tank. Hi Nick, Next time you detect the leak have a look under your seat. I had a problem where the cap under the seat had come loose and fuel was pooling there as I bounced the bike around, just had to tighten it. Andre Whistler, BC.
  • Leaking Fuel Cell GS Dakar. Got back from a long weekend of dicing it up with HD's and Wing's, boy were they surprised that my German weed-wacker could do what it does so well, smoked em good!! Anyway Noticed that gas was dripping slowly when filled and on the side stand. Seems there are hair line cracks around the right side fuel pick up hose of the fuel cell which for a Dakar is directly under my butt. Imagine my surprise when I took the seat off and found the recessed area where the two hose go into the fuel cell filled with 94 octane send ya to the moon highly explosive gasoline. Tom1089 s.c. pa
  • Gas Leak. And I don't mean the bean burrito kind. Past couple of rides I've been smelling gas ('02F650GS). I found a hair-line crack in the large round cap on top of the tank that has the fuel line connections running to it. The crack is between the electrical plug on the right and one of the fuel line connections on the left. Fuel does not puddle, but seeps out slowly. The plastic surface in the area of the crack is not smooth like the rest of the plastic. Looks like a defect. But, I just had my 6k mile service done and maybe someone left a tool on top of the tank and tried to press the seat back in place. This is not out of the question since my throttle cable was mis-routed and one of the turn signal plate screws was cross threaded (previous post). I remember someone on this board with the same fuel leak problem. Has anyone else experienced this? If so, can you rule-out the "tool left on top of the tank" scenario? I'm wondering if this is another fuel tank defect issue. Rod, CO '02GS - 15-Aug-02
  • We pull in to get gas tonight. Fill mine, turn away, turn back and I've got gas gushing all over the place. Holy Moly! Appears that I have a crack in the fuel pump assembly cap....just like the FAQ. Easy to see. Here's the kicker. Himself fills his, turns around and his is puking too!!! Same deal. Huh? At the same time?. Took them apart this a.m. Crack was understating it. His looks like a spider web. Mine's actually in pieces. Have a hard time thinking that gas would make them explode. Went back and read the stories. Three of us in NM, one in Colorado, one in South Africa and the others unnamed locations. Suppose heat and/or altitude contributes? Ours cracked just where you said, but cracked in multiple locations. Totally trashed. Shelley798.
  • I've had the same problem, fixed under warranty. It could be either a design problem or materials/workmanship problem or some combination of both. I tend to believe it is a design problem and I wonder if BMW has redesigned the part. It is a serious problem with a potential for someone getting seriously hurt. It looks like the fuel pump/filter assembly is cantilevered (down) from the round flange that you see on the top of the tank. Mine cracked near one of the web sections that stiffen the flange. If both of you rode through the same places/same speed it would have put the same dynamic loads on the fuel pump/filter assembly and could have resulted in both flanges cracking. Someone with some time and a finite element package could investigate the design. If there really is a problem and BMW ignores it and someone gets hurt, some lawyer somewhere will hire an engineer to investigate the design. I discovered mine was cracked only after a fill up when, like most, fuel started leaking out. I had smelled fuel the days before I noticed the actual leak. Anyway, since it only leaked at the top, I tilted the bike for a while to let the fuel leak out and get the level down below the crack so I could ride it up to Sante Fe to get the tank replaced. So, I wasn't really stranded, just rode a bit dangerously for a few miles. Barrett ABQ.
  • Earlier this year I had the tank on my bike replaced (under warranty) because it was gushing fuel down the dimpled panels every time I filled up. I believe the problem was in the filler tube area in that instance. 6 months with no problems and now......it's happening again. I took the seat off in the garage one night when it was full to observe carefully and it is clear that it seems to be coming out of the circular part of the tank (which looks like a big screw top, if that makes sense) which has the various pipes and hoses coming out of it. Does anyone know if this is part of the moulding, or a separate part which could be cinched tight in some way. I'm hopeful that my dealer will get the tank replaced again under warranty but it is such a pain to be without the bike (and to have to ride a loaner Yamaha 125 SR....) Any similar experiences? Repoman
  • I had just filled up on the way home, and I when I pulled into the garage I smelled some serious fumes. I pulled the seat off, and I saw the image above. I sopped up most of the gas (how many of you can say you've used a diaper to work on your motorcycle? - I figured it was the most absorbant thing around the house :-), but it is still seeping out slowly. Some other questions... Any way to depressurize the system to stop the seepage? What are those connectors for? Gas doesn't conduct electricity very well, right? Do I need to worry about something shorting out? Would I be nuts to ride this ~2 miles to the dealer? I already rode about 5 miles home from the gas station. MichaelC#941

• Is there some kind of epoxy that will truly fix something like this? I suspect this is a warranty item, but if I can fix it myself with very little time involved . . . Or maybe the crack will grow? Scott, ID #1244
• Many automotive stores will carry a epoxy or resin. Make sure you check it is safe to use on fuel tanks AND plastic. Winter #1935
• Here's a link on how to weld plastic. I'm sure this will be cheaper than buying a new tank if you're out of warranty (doesn't sound like it) or if a new one cracks again after you're out of warranty. NothingClever #1441

• Because of the Emissions Canister, that fits in a recess moulded into the US Tank. You can buy the Euro-spec Tank from Touratech, for all of 1.5l extra fuel, and a lot of $$. Or get it off a Euro-wreck. by David H Park #711
• 

  Feedback:

  • I have a '01 F650GS and I have always wondered what is maximum fuel capacity? The brochure for the '03 F650GS/ Dakar lists it at 4.0 gallons but I recall that one time the fuel pump indicating that I put in 4.15 gals. Was the pump inaccurate or does the '01 hold 4.25 gals??? I know that bikes sold outside the US hold more fuel because in order to install the emissions cannister BMW designed a modified fuel tank for the USA. Has anyone drained the tank and then refilled it to see what they actually hold? I realize that without a fuel gauge we all just ride till the warning light goes on and then look for a gas station. As a footnote: my bike seems to be getting better fuel mileage as I accumulate the miles. I haven't changed the fuel filter in over 24K miles and on the last tank the warning light didn't go on till 196 miles :>) Dave. Inmate # 717 - '01 F650GS
  • I didn't have my Dakar long enough to get that familiar with it, but my Classic would hold 0.5 gallon more than the specs detailed. I'm guessing that the specs list what the tank will hold if it meets absolute minimum manufacturing tolerance. That way if someone runs out of gas, they can't be held liable in some fashion. Harl #380
  • The BMW website lists 4.4 gallons for the GS as its fuel capacity. My yellow fuel warning light goes on when 3.2 gallons have been used. echo
  • My Rider's Manual (US Model) says total capacity 4.6 Gallons (17.3 Liters). Warning light is supposed to come on when the tank is down to approximately 1.1 gallons (4 Liters). '03 black F650GSA, Runaway #1259 (CO)

• The charcoal canister is emissions related. The charcoal filter it contains is in the vent loop. The thinking is that when you fill the tank it keeps all those nasty gas fumes that occupied the "empty" part of the tank from floating free. Except the fuel nozzle doesn't cover the fuel filler opening while pumping so it does exactly fuck-all. It connects via an electronic solenoid and then back into the engines intake tract.

• How long is a piece of string? There is no one number. So many factors, Tire Pressures, Laden Weight, Exhaust, Aftermarket Fuel Moderators, Wind, Air Filter Condition & Type ....So here's some feedback. Classic holds 4.6 gals. vs. GS 4.4. Assuming both in 1st class operating condition, they are comparable. The GS does a bit better on mpg but the older Fs hold a bit more fuel so the overall range is pretty much the same.
• Conversions: For those in the US: a UK (imperial) gallon is 4.55 litres. A US gallon is 3.79.
  Which is 1 Imperial gallon = 1.2 US gallons
  Thus, US mileage for a reported 50mpg (UK) = 50 / 1.2 = 42 mpg (US)

  Here's a Good Converter

• This newer version of the F650 seems to be getting considerably better mileage than the old F, largely due to Fuel Injection. Mileage of 55-65 mpg seems to be very common with some reports close to a ridiculously high 70mpg!
• So it must be the fool injection that gives me over 60 mpg regularly on my Dakar. It has even hit 70 a couple times. No kidding. I checked mine yesterday while playing hooky from work...70.76923. SScratch '01 Dakar Nashville
• I have noticed that if I use my bike to drive to and back from work every day, then in the winter the m/tank is a lot worse than in the summer. I got really worried last winter when my m/tank dropped to around 130, but in the summer I was getting my original 200ish. Adam 906NC '01 GSD
• On F650GS my best mileage was 62 miles/US gallon. I went 210 miles before hitting the reserve light. I had the wind in my back. Sojourner, 2000 F650 GS. Toronto, Canada.
• Last weekend I took my 02 Dakar on an 800 mile trip. Fully loaded: 240 pounds of me, sidecases and tankbag full, large dry-bag with full camping kit. A real range of riding, including long 80 mph superslab legs, county two-lanes, hilly twisties, fast fire roads, and slow gravel. A lot of it was pushing the bike pretty hard to keep up with buddies on Boxers and K bikes. Corner exits at Full War Emergency Power were the norm. Trip average: Around 52-54 mpg. For what it's worth, this is what I commonly get at the pump. DakotaDakar on Advrider.
• I have kept accurate records of every fill since new in July last year now have 7,000 Klms on the clock my average per tank on highway running at 90/115 klms/hr is 400 klms., absolute maximum was 420klms.Off road is approx 10 % less max on reserve was 108 klms. Hope this helps. Aussie-John #334
• My 2001 GS goes an average of 180 miles before the low fuel light comes on. I have gone to 220 miles w/o refuelling, and put 4.0 gallons of gas in the tank. This is mostly freeway driving, 60-80 mph. I get better mileage at lower average speeds. Also, my mileage started going up when I hit 10,000 miles, now an average of 55 mpg. The motor also started getting smoother, and is even smoother now at 12,000 miles. YMMV. Dan#823 in Orange Cty, CA - 28-Mar-02.
• Gas mileage. I have nearly 3000 miles on my GS since last October, and have gotten a low of 60 to 62 to a high of 71.6 using premium gas not bad ! Andy - 30-Mar-02
• Usable tank capacity. Remembering speedo error, In kilometres, I can get 300 before the fuel light comes on, and then 100 more on reserve (light "on") for a total of 400 kilometres. This is not driving easy by any means...a mix of cruising and spirited playing. When refuelling, the most I've put in at this 400 point is 16.2 litres, and if the tank truly does hold 17.5 litres, that left me with 1.3 litres in the tank. Approx 67 miles per imperial gallon ...confused yet? 16.2 divided by 4.5 (amount of litres in an imp gallon) equals 3.6, 400 kilometres multiplied by .6 equals 240 miles, 240 divided by 3.6 equals 66.67 mp imperial gallons, 66.67 multiplied by .8 (Imp gallon to US, help me here) equals 53.34, If you were to use all 17.5 litres (3.89 imp gallons) and multiply it by my 66.67 miles, you should get around 259.35 miles per Imperial gallon, or 207.48 US gallon, If my math is off, please adjust and post. I was up late last night. RDW #1134.
• Dakar consistently gets 65 to 70 under normal conditions of 70/75 mph. Not much less when you really hammer it. DirtDOG on Advrider
• I get between 65( on crappy winter gas) to 72 MPG. Usually around 68MPG. Regular F650GS. Wings on Advrider
• I average between 65 and 70. It goes a littler higher when spacewife is riding it. When I am out having too much fun on the 650, like when I followed you guys up to Monterrey, I only got about 50 mph, but that was with the throttle wide open most of the time. PhilSpace on Advrider
• 50-59, depending on how hard I hammer it. ShaftEd on Advrider
• I spent a month on a loaner F650GS (non-PD model), and averaged 60MPG most of the time. I had a blast, would love one if they weren't so damn expensive.... Its a great bike for our local goat trail roads. Advrider
• Wifey is getting 65+ the way she rides. My son swears he got 75 mpg when he borrowed it. Ruskie on Advrider
• For some reason I kept a record on my F650GSD, never done it before, probably won't again. But for WIW here's the overall picture. Average from Start:
  Total Kms 19205 Total Fuel 843.27L Kms/L 22.80 L/100Kms 4.39. Best: L/100Kms 3.56 Kms/L 28.08 Max. Kms 485.80. Worst: L/100Kms 5.17 Kms/L 19.33 Max. Kms 334.47. George on Advrider
• L/100km drives me nuts. Lets see. in 'murkin, he said...Average from Start: Total miles 11933, Total Fuel 222.7 Gallons 53.6 MPG, Best 66 MPG Max. 301.8 miles
  Worst 44.46 MPG Max. 207.8 miles.
• 45.01607717, 41.30154639, 48.80798969, 45.77691812, 46.72609899, I am only driving 3 miles to work and 3 miles back, mostly. Not much else until the winter ends, if it ends. Hopefully it will improve when I start to ride it more. Padraig on Advrider
• Runs consistently that short are bad for the engine, it never gets fully warmed up, and moisture condenses on things inside the engine... you really should try to take it a few more miles at least once a week, maybe stretch the ride home to 10 miles once in awhile. Marty on Advrider
• At one time I was getting 65-68, I haven't checked for a while. Last summer on the way to AZ, I got 58 trying to keep up w/ Jock and Mully. Bird on Advrider.
• I am getting 55 mpg consistently on my '01 Dakar riding solo on twisty backroads. I am usually running between 3500-5500 rpms, 3rd-5th gears. This is just the first 1300 miles, though. I'm hoping it gets even better after breaking in a little more, maybe not. SScratch '01 Dakar Nashville.
• Best economy: 3.6 l/100km Worst: 5 l/100 km Lance, #1303, '01 F650GS.
• I have been getting 22-27km/L (no idea of conversion to gallons) depending on throttle action and headwinds. I just had a Remus exhaust fitted and got a bit better - 27.5 at around 110 on the highway. That's 51.7 - 63.5 MPG
• In summer my kind of riding gets 62 mpg whereas this winter same riding (maybe a little shorter avg distance) and I'm getting 50 mpg echo F650GS Dakar, Camden, New Jersey.

• Depends on your mileage of course!
• On F650GS my best mileage was 62 miles/US gallon. I went 210 miles before hitting the reserve light. I had the wind in my back. Sojourner, 2000 F650 GS Toronto, Canada
• The yellow low fuel light came on going home last night after 189 miles since last fill up. It took 3.2 gallons to fill the tank one mile later. It seems I've gone that far before but cant remember the light going on. How many gallons do listers put in their tanks when the low fuel light comes on? (01 Dakar) I seem to remember the tank is 4.5 gallons with .5 gallon in reserve. echo
• I filled mine today shortly after the light came on and it took 3.2 gallons too. F650GS. Sam#1238MI
• "Your mileage may vary"... Depending on how fast you go, the light may come on sooner than later. I've gotten as many as 225 miles (lazy, winding country roads) and as little as 165 miles (super slab, 85+mph) before the light came on. Savant of the pavement
• Light comes on when I've used 3.2gal on my '02 GSA, typically 210 highway/road miles. Seems like this is the consistent answer (very precise light! Accuracy is another story.), so lots left when in comes on. Cheers, Greg #1245
• I have a 2001 GSA. If I do almost all freeway miles at 75+ mph, I get about 170 miles before the light comes on, and I fill with about 3.2 gallons if I don't go too far after that. If the riding mixture is more toward twisties and relaxed riding at about 50 mph average, I can get over 200 miles before the light goes on. I rode the tank dry once, within 50 yards of a gas station (Talk about luck!), and it took 4.2 gallons to fill. My impression is that my mileage went up as I approached 12,000 miles on the bike and remained about the same thereafter, but I don't keep the kind of records that would verify that. Dan #823 (Southern CA)
• Hmm, low fuel light comes on with 1.3 gallons remaining in tank on these bikes. Good to know! echo
• I was told by my dealer that about 2 liters are unreachable by the fuel pick-up. Keeps the water and crud from getting sucked into the filter. Keith in Alaska #714
• 3.2 gallons most every time. Scott, ID #1244
• My '01 GSA's low fuel light comes on at 150 miles in warm summer weather and 125 in cold winter weather, the tank takes 3.2 gals at the pump each time. My driving is zero freeway, all stop and go country 2-lane roads (Bainbridge Island) and city stoplights (Seattle). About 15 miles round trip daily commute. I flog the engine and rev 'er up to 5000+ at each shift. I'm not trying to save gas and it shows, but it is fun to drive this way. Snapper1065.
• Hi guys & Gals--I know we have just covered this but...2nd tank on 02 Dakar Reserve on at 167 miles. Topped off at 3.23 gallons.. 52 MPG --- tank w/out reserve should have gone to +- 200? What am I figuring wrong. Mileage is GREAT for my fat ass. Question I have is at 50+ MPG reserve light should not be on until 200+ miles if tank is 4.5 gallons w/ .5 reserve. Right? I think the US tank has only 4.1 gallons total, because they had to create a space for the cannister :-(. Capacity per 02 Specs from BMW website is 4 Gallon w/ .7 reserve. Makes my math perfect. Barry
• Well the one time I ran my Dakar out of gas (intentionally) to check distance on the tank I took 4.45 gallons according to the meter at my local Texaco and had traveled 267 miles. I don't pay much attention to reports of how far to the low fuel light as this is adjustable and seems to vary a good bit from bike to bike. But I always get over 200 before I fill unless I am really running hard into a headwind. Homeless

In preparation to ship my bike I was going to use a siphon hose to drain the gas tank on my 2001 F650GS. Are there any other recommended ways to drain the gas tank? Is there a hose that is hidden that I can may disconnected to let gravity do the work. Please remember that this is a 2001 fuel injection bike with the gas tank that is under the seat. Rodger (#1046).

• There are two hoses at the tank. The fuel feed line is the one with the arrow (pointing toward fuel filter). The other (return) line has no arrow. Disconnect fuel feed line at fuel filter. You'll need to replace the clamp with a new one. There are two electrical connectors at the tank. One is power to the fuel pump (I don't have the schematics with me to identify that connector). Remove fuel-pump power connector at tank. Run two wires from the battery to the exposed pins at the tank. You *MUST* get the polarity correct! I've drained the tank before, prior to removing the rear subframe to change shims (Can you say "GS with ABS?; I knew ya' could."). In this situation, the fuel filter and battery are already exposed and accessible. In your situation, it might be easier to just use a siphon. If you plan to use the fuel pump to drain the tank, you *MUST* get the polarity correct! Raymo #1173, Chicago, 2001 F650GSA
• When I tested my fuel pressure I just connected the hoses (together) and put the ignition ON. With no back pressure the pump will run until the ignition is turned off. Just remember the system is under pressure, so when the hoses are removed some petrol will squirt out. (remove the fuse for the headlight first to avoid draining the battery too much). Running the fuel pump dry will destroy it, so better be observant during the draining. It has a lot of pumping capacity so be careful. Haakon #626

• The Polarity is (To be advised)

• Check the globe (you will need to take part of the dash apart)
• Note: The fues for the fuel light is the same one used for all the dash, so if the fuse has blown you would have no lights on the dash at all
• The low fuel circuit appears to be rather simple. One side of the bulb is always hot at 12v. One side of the switch, in the fuel tank, goes directly to ground. The low fuel switch in the gas tank is just a float attached to the switch. At low fuel level it completes the circuit between the ground at the switch and the 12v at the bulb.
  
  I had 12v at the bulb and a good ground at the switch. I pulled the switch out of the tank and by manually operating the float, it completed the connection to ground. This told me I had a break in the wire between the switch and the bulb. I didn't want to rip the wiring harness apart to find the break so I just ran a new wire from the switch to the bulb. The circuit now works fine. StmbtDave
  
  Before you try this:
  1. check the bulb (swap with another one you know works)
  2. check that you have 12v on one side of the bulb (with the key on)
  3. check for a good ground at the switch (brown wire)
  4. pull the fuel pump/switch assembly and verify that the switch works
• Much quicker...... Pull the seat off. One connector on top of fuel pump goes to pump. The other connector goes through the switch. Use the schematics to figure out which is which. Jumper the two conductors on the plug side of the switch plug.
  The low fuel light comes on= faulty or mis-adjusted switch in tank
  Light does not illuminate= faulty bulb or wiring.
  It takes less than 2 minutes to do this and it will tell you so much. jetdocs550 #1546

• Has anyone had a problem with their fuel light coming on too soon. Mine comes on when there is still 2 gallons left in the tank. I ride about 25 miles after the fuel light comes on and then refuel and it only takes 2.8 Gals. They replaced the whole fuel module and now it is slightly better as it took 3.1 gals this time after riding 25 miles. honeybrk
• That seems way too soon. When my '05 low fuel light comes on, it takes me approx 3.4 gals to fill it up. A.T. #1625

Yes. On the left side of your bike there should be a small tube coming out near the center stand. This tube runs up to the highest point of the tank. If you remove the seat you should see the overflow pipe running up to the tank behind the BMS-C / Fuel Injection computer.

• It seems to me that the fill opening on the GS is relatively in its highest position while on the side stand (because it's on the side of the bike), unlike the bike with the filler in the top center, which would be highest while on the centerstand. djw #1736
• I fuel on the side stand and rock the bike to expel any air so I can fit in max fuel load, especially when on a trip. I sometimes carry extra fuel in bottles but NEVER allow the machine to actually run out, as it can possibly cause accelerated wear on the roller cell fuel pump. jack #1977
• A fair question. Intuitively, I'd think that for the GS you could get more in with it on the sidestand. You never really know though? If anyone ever takes their tank off for whatever reason do two tests with gas or water at the two attitudes. You could weigh it. I guess right now we could fill it up to the brim on the sidestand, shut the flap, put it up on the centerstand, open the flap and see if any runs out or it's lower. motoplaner #1671

• Is it just me, or is the little metal piece that holds the gas filler cap closed as ABSOLUTELY UNCOMPROMISINGLY ULTRA-SUPER-DAMNED-MINIMALISTICALLY TINY as it can possibly be and still barely function? I hate having to get that cap closed and locked with gloves on. And I have this nagging suspicion that over time it's going to wear down and at some point fail to latch properly. McGuireV10
• hey now... the manual in my 03 does say to use the key to close the fuel cap. So if you are concerned about the cap wearing down... just use the key to open and then close the thing!!! Easy one! FIUF650
• I do not use the key. I push down firmly until I hear the satisfying "click" telling me that the cap is locked. If I own my bike for 100,000 miles and get about 210 average miles per tankful. My limited high-skooo math tells me the gas cap will have 477 cycles on it in 100,000 miles. I'm not terribly worried about wearing it out. jetdocs550 #1546

• No

• does anybody else have their black fuel tank turning greyish from UV (presumably) and if so are there any products you use or reccomend to protect the plastic. my bike isnt garage kept and i only cover it when i am gone for a long time. also i got it used and it was faded when i got it. colin
• From information I have been told, the plastic panels are painted. replacement panels can be purchased either painted OR unpainted, according to thye BMW parts listings. I THINK BMW use Standoz paint, from memory. YMMV jack #1977

RevJVegas: Using paper towels, and a cigarette lighter to see what I was doing, I mopped up all the gas.
pwendell: Uh, Raj, you didn't really use a cigarette lighter to look at a gas leak, did you?
RevJVegas: No I didn't really...just checking to see if y'all are paying attention.
pwendell: I am relieved. I'd hate to hear about an Inmate going up flames, it'd be a waste of a nice bike too