2006 BMW R 1200 Gs

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

TL* THE CONTACT OWNS A 2006 BMW R-1200 GS. THE CONTACT STATED THAT UPON START OF THE MOTORCYCLE, HE NOTICED THAT FUEL BEGAN TO SPEW OUT OF HIS MOTORCYCLE. THE CONTACT CALLED WAGNER MOTORSPORTS (700 PLANTATION ST, WORCESTER, MA 01605) WHERE HE WAS INFORMED THAT HE WOULD HAVE TO BRING IN THE MOTORCYCLE FOR INSPECTION. THE MANUFACTURER WAS ALSO NOTIFIED OF THE FAILURE AND THEY INFORMED HIM TO TAKE THE MOTORCYCLE TO A DEALER TO BE SERVICED. UPON INVESTIGATION, THE CONTACT DISCOVERED NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM, GASOLINE) WHICH HE LINKED TO HIS FAILURE. NEITHER THE DEALER NOR THE MANUFACTURER NOTIFIED THE CONTACT WHETHER HIS MOTORCYCLE WAS INCLUDED IN THE RECALL. THE VIN TOOL SHOWED THAT THE MOTORCYCLE WAS NOT INCLUDED IN THE RECALL. THE VEHICLE HAD YET TO BE REPAIRED. THE FAILURE MILEAGE WAS 22,000.

NHTSA ID

11353005

Incident

Aug 26, 2020

Mileage

22,000 mi

TL* THE CONTACT OWNS A 2006 BMW R 1200 GS. THE CONTACT STATED THAT THE REAR WHEEL CARRIER WAS FRACTURED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FLANGE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.

NHTSA ID

10652059

Incident

Jun 13, 2014

Mileage

40,000 mi

THE REAR WHEEL ASSEMBLY/SWINGARM IS DESCRIBED BY BMW AS "MAINTENANCE FREE," MEANING THAT THE OIL LEVEL IN THE REAR SWING-ARM CANNOT BE CHECKED OR REFILLED. MY MOTORCYCLE HAS DEVELOPED AN OIL LEAK FROM SAID ASSEMBLY, AND HAS BEEN SLOWLY LEAKING FOR THE LAST 10,000+ MILES. IF THE OIL LEVEL DROPS LOW ENOUGH, I FEAR THE REAR WHEEL COULD LOCK WHILE RIDING, RESULTING IN A CRASH. *TR

NHTSA ID

10578505

Incident

Feb 17, 2010

Mileage

25,000 mi

WITH TURNING ON THE KEY, FUEL LEAKED OUT OF THE LEFT SIDE OF THE MOTORCYCLE. THE LEAK COMES FROM THE FUEL LINE ATTACHMENT TO THE FUEL PUMP MOUNT ON THE LEFT SIDE OF THE FUEL TANK. THE FUEL SPRAYS OUT OF THE PLASTIC FUEL PUMP MOUNT WHEN THE KEY IS TURNED ON. THE PLASTIC CONNECTION IN THE FUEL LINE HAS CRACKED. THIS SEEMS VERY DANGEROUS. *TR

NHTSA ID

10535545

Incident

Aug 12, 2013

Mileage

19,375 mi

SMELL OF GASOLINE WHILE RIDING. DISCOVERD FUEL LEAK FROM CRACKS IN PLASTIC FLANGE WHERE FUEL LINE ATTACHES TO FUEL TANK. FOUND OUT THIS IS A COMMON FAILURE. NEW MODELS HAVE A UPDATED PART. *TR

NHTSA ID

10508135

Incident

Apr 6, 2013

Mileage

47,400 mi

AFTER STOPPING AT LOCAL GAS STATION TO FILL UP WITH GAS AS PER NORMAL, NOTICED GAS SMELL, BUT COULD NOT DETECT ANY VISIBLE LEAK. RODE FOR A SHORT DISTANCE, RETURNED HOME. AFTER STOPPING ENGINE AND DISMOUNTING, NOTICED MY LEFT PANT-LEG WAS SOAKED IN GASOLINE. AFTER REMOVING SIDE [LEFT] PANEL WAS ABLE TO SEE VISIBLE FUEL LEAK (MORE OF A SPRAY). LEAK ONLY OCCURRED WHEN FUEL PUMP WAS OPERATING. SOURCE OF LEAK WAS THE FEMALE CONNECTOR OF THE FUEL LINE. *TR

NHTSA ID

10493015

Incident

Dec 1, 2012

Mileage

63,000 mi

WHILE RIDING THE VEHICLE ON SEPTEMBER 11, 2012 I NOTICED A STRONG FUEL SMELL. WHEN I ARRIVED AT MY DESTINATION MY LEFT PANT LEG WAS SOAKED IN FUEL. AFTER FURTHER INVESTIGATION I DETERMINED THAT THE FUEL PUMP HOUSING HIGH PRESSURE FUEL DISCONNECT FLANGE WAS CRACKED AND LEAKING FUEL DOWN THE LEFT FAIRING IN CLOSE PROXIMITY TO THE VEHICLES LEFT EXHAUST PIPE AND IGNITION. MY EXPERIENCE MATCHES THAT OF ODI ID NUMBER : 10428629. *TR

NHTSA ID

10475150

Incident

Sep 11, 2012

Mileage

39,280 mi

FUEL PUMP FLANGE IS CRACKED, ALLOWING 40PSI OF FUEL PRESSURE TO STREAM OUT OF TANK. GREAT RISK OF FIRE AS FUEL LANDS DIRECTLY ON EXHAUST. THERE WAS ONLY NO FIRE BECAUSE I NOTICED THE LEAD AND SUBSEQUENT PUDDLE OF FUEL BEFORE BIKE/PIPES GOT HOT. *TR

NHTSA ID

10474390

Incident

Sep 9, 2012

Mileage

5,500 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.