2008 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

MY BMW MOTORCYCLE WAS STATIONARY AT THE TIME BUT WITH A BRAKE FAILURE WARNING LIGHT INDICATED ON THE DISPLAY PANEL ONCE THE IGNITION WAS TURNED ON AND THE MOTORCYCLE ENGAGED TO BE RIDDEN THE MOTORCYCLE HAS LESS THAN 5,000 MILES ON IT. AFTER DOING SOME INTERNET RESEARCH, THE ABS MODULE IS COMMONLY FAILING AT AN ALARMING RATE THROUGHOUT THE USA AND ABROAD. THE ESTIMATED VALUE OF THE REPAIR WITH PARTS ALONE IS OVER $2,000 NOT INCLUDING LABOR. THESE UNITS SHOULD HAVE BEEN RECALLED BY THE MFG., BMW YET THERE HAS BEEN NO SUCH RECALL. BMW HAS MADE NO ACCOMMODATION TO EXTEND THE WARRANTY OR PROVIDE A REPLACEMENT DESPITE BEING WELL AWARE OF THE FAILURE RATE OF THESE ABS UNITS. OBVIOUSLY, A FAILURE OF THIS MODULE COULD CAUSE SEVERE INJURY OR DEATH WHILE OPERATING THE MOTORCYCLE.

NHTSA ID

10825853

Incident

Feb 11, 2016

Mileage

4,800 mi

TL* THE CONTACT OWNS A 2008 BMW R1200 GS ADVENTURE. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT NOTICED AN ENGINE OIL LEAKAGE FROM THE REAR DISK THAT LEAKED ONTO THE REAR TIRE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 56,591.

NHTSA ID

10745206

Incident

Jul 17, 2015

Mileage

56,591 mi

IN HAVING THE BIKE SERVICE WAS INFORMED THAT THE ABS PUMP UNIT HAS FAILED AND DID SOME TIME AGO. THIS IS HAPPENING ON MANY BMW MOTORCYCLE FROM THE R AND K CLASS OF BIKES AND COULD CAUSE COMPLETE BRAKE FAILURE UNEXPECTEDLY WHICH WILL CREATE SERIOUS INJURIES

NHTSA ID

10736105

Incident

Jul 1, 2014

Mileage

31,000 mi

I WAS RIDING ON THE CENTRAL FREEWAY ON THE BAY BRIDGE APPROACH WHEN I BEGAN TO FEEL HEAT ON MY LEFT INNER THIGH. I ALSO NOTICED A BURNING RUBBER OR PLASTIC SMELL. I IMMEDIATELY BEGAN MERGING TO THE RIGHT AS I WAS APPROACHING THE LAST SAN FRANCISCO EXIT BEFORE THE BAY BRIDGE. I FOUGHT MY WAY THROUGH THE HEAVY TRAFFIC ALL WHILE LOOKING DOWN TO SEE WHAT LOOKED LIKE EMBERS DROPPING OFF THE LEFT SIDE. I PULLED INTO A SHELL STATION, JUMPED OFF AND PULLED THE BURNING SEAT OFF OF THE MOTORCYCLE AND PATTED IT OUT. I FOUND THAT THE FRONT SEAT RAIL HAD BECOME DISLODGED (IT IS ONLY HELD IN PLACE BY A RUBBER STRAP THAT IS LOOSENED TO ADJUST THE SEAT HEIGHT) AND RUBBED THROUGH THE PROTECTIVE COVER OF THE POSITIVE BATTERY TERMINAL AND ARCED TO THE FRAME. THE SEAT AND THE SEAT BRACKETS WERE MELTED. I WAS ABLE TO COVER UP THE DAMAGED WIRING AND BATTERY ENOUGH TO ALLOW ME TO SAFELY RESTART THE MOTORCYCLE TO HAVE THE DAMAGE EVALUATED BY A SHOP (BAVARIAN CYCLE WORKS IN SAN FRANCISCO.) THE DAMAGE WAS PHOTOGRAPHED AND I AM AWAITING PARTS TO ARRIVE FROM GERMANY TO CARRY OUT THE REPAIRS. I HAVE LOCATED A MACHINE SHOP THAT SELLS A KIT TO MODIFY THE SEAT TO PREVENT THIS FROM OCCURRING AGAIN. THE KIT ELIMINATES THE SOLID METAL BAR THAT RUNS ACROSS THE WIDTH OF THE SEAT. IT USES TWO SHORTER RODS ONLY WHERE THEY ARE NEEDED TO LOCATE THE SEAT IN ITS FRONT HOLDER. NEEDLESS TO SAY, I ORDERED ONE RIGHT AWAY. *TR

NHTSA ID

10640696

Incident

Sep 24, 2014

Mileage

19,000 mi

FUEL LEVEL SENSOR INDICATOR FAILED AND NEEDED REPLACEMENT. THIS HAPPENS ON ALL OF THESE MODELS BUT THERE HAS NOT BEEN A RECALL OR EVEN AN ACCEPTABLE FIX FROM BMW. WE ARE ADVISED TO USE OUR ODOMETER AND IGNORE WARNING LIGHTS ON OUR DASHBOARDS. *TR

NHTSA ID

10585138

Incident

Sep 17, 2008

Mileage

6,000 mi

ABS SYSTEM FAILED- REQUIRED THE PURCHASE OF $2500 NEW ABS PUMP CONTROL MODULE. *TR

NHTSA ID

10584035

Incident

Apr 11, 2014

Mileage

30,292 mi

FUEL LEVEL INDICATOR SHOWED EMPTY AFTER REFILLING. FLASHING LIGHTS INDICATING PROBLEM WITH VEHICLE. FILLED UP WITH 1/2 GALLON OF 91 OCTANE GASOLINE TO VISIBLE FULL IN TANK. THE TANK WAS NOT EMPTY, FAULTY FUEL LEVEL GAUGE/STRIP. THIS ITEM HAS BEEN REPLACED IN THE PAST WITH NO APPARENT PERMANENT FIX. *TR

NHTSA ID

10560047

Incident

Oct 15, 2009

Mileage

12,000 mi

ARBITRARY FAILURE OF THE FUEL LEVEL SENSOR. IT OCCURRED AT 2,200 MILES. OPERATION OF THE MOTORCYCLE WAS UNINHIBITED EXCEPT FOR A FALSE READING ON THE FUEL GAUGE. AFTER THE FAILURE AND REPLACEMENT OF THE RECALLED FUEL PUMP CONTROLLER, THE FUEL GAUGE READS EMPTY REGARDLESS OF LEVEL. THIS RESULTS IN A CONSTANT WARNING LIGHT THAT CANNOT BE RESET OR TURNED OFF. THIS PROBLEM IS WELL DOCUMENTED AND A COMMON ISSUE WITH THIS TYPE OF FUEL SENSOR IN THESE MOTORCYCLES. *TR

NHTSA ID

10552598

Incident

Jun 2, 2013

Mileage

2,200 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.