2007 BMW R 1200 Gs Adventure

ODI began investigating this issue after owners of model year (MY) 2004-2011 R-series BMW motorcycles reported incidents of pressurized fuel leakage from the fuel pump flange.Some owners first became aware of the problem when their pant leg was fuel-soaked.Prior to opening our initial investigation on November 16, 2012, BMW had concluded that the small number of warranty claims and owner reports did not indicate the existence of a safety defect trend.However, during the course of responding to our information requests, BMW re-examined its data and decided to conduct a recall (13V-617) of the subject motorcycles.In conducting recall 13V-617, BMW voluntarily expanded the scope of affected vehicles from ODI'soriginal scope, MY2005-2008 R-series motorcycles, to include the primary and auxiliary fuel pumps on all MY 2005-2011 R-series, MY 2005-2011 K12&13 models, MY 2010-2011 RR models, and the MY 2012 K1600 motorcycles.The total number of motorcycles subject to this recalled is 50,184.The 55 reports cited in this investigation can be viewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following complaint identification numbers:10485789,10449393,10521322,10475150,10435325,10493015,10471642, 10448216,10488899,10356156,10433733,10442023,10492342,10435968, 10492961,10504324,10485882,10433013,10453738,10474390,10417320, 10485276,10444876,10508150,10485807,10492118,10491835,10425962, 10430734,10488652,10485274,10493320,10522421,10399423,10443840, 10448325,10490417,10485452,10433589,10467136,10420291,10503806, 10532145,10523763,10523626,10425514,10354202,10437222,10444742, 10454834,10532172,10487624,10435984,10452476, 10485337

Owners of model year (MY) 2005-2008 R-Series motorcycles report substantial, high pressure fuel loss occurring when the fuel pump is energized.Many times they first become aware of the problem when fuel soaks their pant legs or is puddled under their parked motorcycle.The Office of Defects investigation (ODI) has obtained an owner video illustrating the issue.This video, and other material, may be found in the public file at www.SaferCar.gov. ODI has learned that the subject fuel leak is due to cracks in the fuel outlet quick connector located on the in-tank fuel pump housing.While some owners, reluctant to incur the expense to replace the fuel pump assembly, have undertaken frequently ineffective do-it-yourself repairs primarily involving adhesive patches, two other remedies are available.The first, found in the after-market, is an aluminum clamp designed to reinforce the fuel outlet threaded flange.The second is BMW?s own remedy, appearing in early 2011, following introduction of the aftermarket clamp.It, too, involves a metal collar designed to support the fuel outlet threaded flange.In January 2004 BMW conducted safety recall 04V028 involving 2000 to 2004 Model Year K and R Series motorcycles for a pressurized fuel leak.In this case an O-ring in a fuel line quick connector could become damaged and BMW identified the potential for fire as a consequence of this failure.In its recall, influenced by an ODI investigation (PE03-054), BMW judged the fire risk to be low and the fuel loss to be insignificant -- occurring most often during cold starts -- resulting most often from improper servicing of the fuel line quick connector by its dealers. All of the complaints and warranty claims referenced in this resume involve verified fuel leaks rather than owners simply expressing a concern that a leak may develop in their subject motorcycle. With summer approaching and seasonal motorcycle usage increasing, ODI has upgraded PE12-036 to EA13-006 to further evaluate this issue, monitor fuel leak frequency, and determine the risk associated with the alleged fuel leaks.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following complaint identification numbers: 540232, 765847, 10074376, 10159252, 10236289, 10339245, 10356156, 10417320, 10425962, 10430734, 10430822, 10432269, 10433589, 10433733, 10436885, 10437222, 10442023, 10443840, 10444670, 10444742, 10444876, 10445888, 10445954, 10448104, 10448104, 10448325, 10448592, 10449393, 10451907, 10452476, 10453738, 10460566, 10463408, 10463946, 10467136, 10470251, 10471518, 10471642, 10474390, 10475150, 10474390, 10475150, 10480052, 10480834, 10485274, 10485276, 10485292, 10485337, 10485348, 10485351, 10485376, 10485434, 10485452, 10485783, 10485789, 10485796, 10485807, 10485882, 10487501, 10487624, 10488652, 10488899, 10490417, 10490868, 10491835, 10492118, 10492342, 10492961, 10493015, 10493320, 10494927, 10494899, 10495307, 10496593, 10503488, 10503806, 10504130, 10504324, 10508135, 10508150

DESPITE A COMPLETED RECALL FOR THE FUEL PUMP FLANGE, CRACKS IN THE FUEL PUMP DEVELOPED AND LED TO THE FLANGE SNAPPING COMPLETELY INTO TWO PIECES WHILE UNDER PRESSURE. ON A TRIP FROM MEMPHIS TENNESSEE TO RICHMOND VIRGINIA, THE FLANGE BROKE INTO TWO PIECES AND SUBSEQUENTLY COVERED THE RIDER IN GASOLINE AND MADE CONTINUED TRAVEL AN IMPOSSIBILITY. IN ADDITION TO COVERING THE RIDER IN GASOLINE AND RISKING INJURY TO SKIN AND EYES, THE GASOLINE ALSO MADE ITS WAY ONTO THE FRONT TIRE, REDUCING TRACTION, AND ONTO THE FRONT EXHAUST HEADERS, RISKING A FIRE AND/OR EXPLOSION. THIS OCCURRED WHILE THE MOTORCYCLE WAS IN MOTION AT ROUGHLY 55 MPH AND PREDOMINATELY IN A STRAIGHT UP/DOWN POSITION. THE INCIDENT OCCURRED ON A STATE ROUTE OFF OF INTERSTATE 40 NEAR NASHVILLE TENNESSEE.

NHTSA ID

11231788

Incident

Jul 10, 2019

Mileage

92,000 mi

PRIOR RECALL CAMPAIGN 13V-617 FOR FAULTY FUEL PUMPS WAS PERFORMED IN 2014. FUEL PUMP HAS STARTED LEAKING IN THE EXACT SAME MANNER THAT TRIGGERED THE INITIAL RECALL. VEHICLE IS LEAKING FUEL FROM THE SAME PART.

NHTSA ID

11130418

Incident

Aug 6, 2018

Mileage

100,000 mi

THE FUEL PUMP FLANGE CRACKED AND FUEL SPRAYED ALL OVER ME COVERING THE MOTORCYCLE AND MYSELF WITH GASOLINE. THE MOTORCYCLE WAS IN MOTION AND I WAS NOT ABLE TO STOP IMMEDIATELY. I WAS DRIVING TO WORK ON A HIGHWAY AND A SIDE STREET. THE PART THAT CASUED THE ISSUE WAS A FUEL PUMP FLANGE. THIS PART WAS REPAIRED UNDER RECALL 13V-617 IN JULY OF 2015. THE RECALL FIX FAILED AND IS A SAFETY ISSUE.

NHTSA ID

11113287

Incident

Jul 12, 2018

Mileage

15 mi

PREMATURE ABS PUMP FAILURE, WHILE DIAGNOSING INOPERATIVE SPEEDOMETER TECHNICIAN FOUND THAT WHEEL SPEED SENSORS ARE GOOD AS ARE VEHICLE CONTROL UNITS CONNECTED TO ABS MODULATOR BUT THERE IS NO COMMUNICATION FROM THE ABS MODULATOR PUMP TO THE CONTROL UNITS, ABS UNIT TEST AS FAILED, TECHNICIAN RECOMMENDS REPLACE ABS PUMP/MODULATOR TO REGAIN ABS AND SPEEDOMETER FUNCTIONALITY AS WELL AS BRAKE LIGHT. BMW PART# 34517715109 ($1,911.99)

NHTSA ID

10853145

Incident

Mar 18, 2016

Mileage

18,339 mi

FIRST FINAL DRIVE FAILURE AT 51K, SECOND AT 71K, FINAL DRIVE SEAL AT 79K, THIRD FINAL DRIVE AT 85K, FOURTH FINAL DRIVE AT 93K. I HAVE PAID FOR THREE OF THEM, WITH THE LATEST COSTING $2600.00 DUE TO THE HOUSING BEING DAMAGED AND NONE AVAILABLE FROM BMW. ONLY OPTION WAS BUYING BRAND NEW FINAL DRIVE. COMPLAINED TO BMW SAN JOSE DEALER WHO CONTACTED REGIONAL GUY. THEIR SOLUTION WAS TO REFUND ME A THIRD OF THEIR COST OF THE FINAL DRIVE ONLY, A WHOPPING $462.19. CONTACTED BMW NA CUSTOMER SERVICE, WAS TOLD THAT THIS IS FINAL DECISION AND THEY WILL NOT BE DOING ANY MORE. *TR

NHTSA ID

10621015

Incident

Jul 2, 2014

Mileage

93,000 mi

"BRAKE FAILURE" WARNING LIGHT ILLUMINATED. DIAGNOSED BY DEALER AS FAILED ABS PUMP. ABS NOT FUNCTIONING UNTIL PUMP GETS REPLACED. *TR

NHTSA ID

10606843

Incident

Jun 3, 2014

Mileage

30,000 mi

UPON STARTING THE MOTORCYCLE GAS BEGIN SQUIRTING OUT THE RIGHT SIDE OF THE GAS TANK - APPROXIMATELY 1 QUART WITHIN A MINUTE OR TWO, COVERING MY PANT LEG AND FLOOR. UPON REMOVAL OF THE RIGHT SIDE TANK COVER IT WAS APPARENT THAT THE QUICK RELEASE COUPLING WAS SPLIT OR CRACKED AND WOULD SPEW GAS ANYTIME THE IGNITION WAS TURNED ON. THIS IS A VERY LOW MILEAGE HIGHLY MAINTAINED MOTORCYCLE KEPT IN A TEMPERATURE CONTROLLED GARAGE. THIS COULD HAVE BEEN A SERIOUS SITUATION HAD I BEEN RIDING AT SPEED AND THE GAS IGNITED. MY BMW REPAIR FACILITY INDICATED THAT THIS IS A COMMON FAILING AND SOLD ME THE REPLACEMENT PART THAT IS THE IDENTICAL PLASTIC COUPLING I REMOVED. *TR

NHTSA ID

10568870

Incident

Feb 17, 2014

Mileage

875 mi

FUEL PUMPS WERE FOUND CRACKED WITH BROKEN SEALS AND LEAKING DURING NORMAL SERVICE. *TR

NHTSA ID

10557172

Incident

Dec 3, 2013

Mileage

89,000 mi

The electrical system of BMW vehicles has been subject to an ongoing development process over the last few years. This has led to increased demands being placed on the battery. This document covers important information for the dealer on how to handle “discharged battery” complaints.

Since October 2023, a new maintenance schedule is valid for all K5x models. For the first time, maintenance positions for the cardan shaft (Driveshaft) are included. NOTICE: 1. The new maintenance schedule is not limited to vehicles affected by the SI 33 02 22 (SERVICE ACTION: Swingarm Drain retrofit and Driveshaft Check), but is valid for all K5x models - including retroactively. In case of retroactive validity (model year 2023 and older), affected customers will be informed about the change. This will be in the form of a direct-to-customer letter with a description of the new maintenance schedule, specific owner’s manual insert, and consumer warranty book insert. 1. For vehicles affected by SI 33 02 22 (SERVICE ACTION: Swingarm Drain retrofit and Driveshaft Check), this service action must be performed first. All conditions described in this bulletin apply after the open Service Action has been completed. No additional communication is required for K5x models model year 2024 and onwards. Those models have the new maintenance schedule in their owner’s manual.

BMW Motorrad USA has become aware of a potential durability issue with the film type fuel level sender “Fuel Strip” equipped on certain model year 2005 to 2013 R and K series motorcycles.

Multiple factors may cause the driveshaft to become damaged; among them are corrosion in certain parts ofthe driveshaft, and wear and tear exacerbated by certain climatic conditions.

BMW Motorrad is aware of a number of cases in which the screw connections of the Paralever link and/or the rear brake caliper have loosened in customer vehicles while driving.

Multiple factors may cause the driveshaft to become damaged; among them are corrosion in certain parts of the driveshaft, and wear and tear exacerbated by certain climatic conditions.