2008 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

The contact owns a 2008 BMW R 1200. The contact stated that while the motorcycle was parked, the contact smelled fuel on several occasions. No warning light was illuminated. The motorcycle had not been diagnosed or repaired. The manufacturer was made aware of the failure and determined that the VIN was not included in NHTSA Campaign number: 20V471000 (Fuel system, Gasoline). The failure mileage was approximately 69,000.

NHTSA ID

11555710

Incident

Oct 22, 2023

Mileage

69,000 mi

Fuel strip sensor failure. The fuel strip sensor that sends fuel level information to the motorcycle dash has failed. This is a known issue by BMW. When the strip fails, it no longer sends accurate fuel level information and the fuel indicator on the dash is no longer reliable. In my case, the fuel level reads full permanently even though fuel has been completely depleted. BMW's remedy is/was to replace the faulty fuel strip with another of the same faulty design rendering a situation where the rider can never rely on the fuel gauge. There are no warning lamps, messages, or other symptoms prior to the issue which results in unsafe riding conditions when the engine suddenly dies unexpectedly from lack of fuel.

NHTSA ID

11528242

Incident

Jun 9, 2023

There is a small plastic cam on the throttle body that gets pulled by the throttle cable to control the butterfly valve. They break easily and cause a loss of power and engine control. I have seen many others posting on line with same issue

NHTSA ID

11466015

Incident

May 24, 2022

The contact owns a 2008 BMW R 1200 GS Motorcycle. The contact stated the vehicle was leaking fuel without warning. The contact called the local dealer but the vehicle was not diagnosed or repaired. The manufacturer was notified however, no further assistance was provided. The approximate failure mileage was 35,000.

NHTSA ID

11439387

Incident

Oct 28, 2021

Mileage

35,000 mi

TL* THE CONTACT OWNS A 2008 BMW R 1200 GS MOTORCYCLE. THE CONTACT STATED THAT THE MOTORCYCLE FUEL SENSOR STRIPS WERE REPLACED THREE TIMES, UNDER THE MANUFACTURER WARRANTY REPAIR. THE CONTACT HAD TAKEN THE MOTORCYCLE TO IRON HORSE MOTORCYCLES (344 E. GRANT RD, TUCSON, AZ, 85716, (520) 327-0773 AND THE THIRD FUEL SENSOR STRIP WAS REPLACED HOWEVER, THE REPAIR FAILED TO FIX THE FAILURE. THE CONTACT STATED THE FUEL TANK READ EMPTY WHETHER THE FUEL TANKS WAS FULL OR EMPTY. THE MOTORCYCLE WAS NOT REPAIRED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE FAILURE MILEAGE 50,956. *BF

NHTSA ID

11383357

Incident

Jan 1, 2014

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2008 BMW R 1200 GS. THE CONTACT STATED THAT WHILE DRIVING AT 70 MPH, WITHOUT WARNING AN ABNORMAL ODOR APPEARED AS FUEL POURED ONTO THE CONTACT. THE CONTACT COASTED THE MOTORCYCLE TO THE SHOULDER OF THE ROADWAY AND CONTACTED HIS FRIEND WHO HAULED THE MOTORCYCLE BACK TO THE CONTACT'S RESIDENCE. BIG #1 MOTORSPORTS (505 COBB STREET, 1-65 & OXMOOR RD BIRMINGHAM, AL 35209) WAS CONTACTED AND INFORMED THE CONTACT THAT THE MOTORCYCLE WAS PREVIOUSLY REPAIRED UNDER NHTSA CAMPAIGN NUMBER: 20V471000 (FUEL SYSTEM, GASOLINE). THE MOTORCYCLE WAS NOT REPAIRED A SECOND TIME. THE CONTACT STATED THAT THE FUEL TANK WAS PREVIOUSLY REPAIRED THREE TIMES. THE MANUFACTURER WAS CONTACTED AND INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 20,000.

NHTSA ID

11364332

Incident

Aug 29, 2019

Mileage

20,000 mi

FUEL IS LEAKING FROM GAS TANK FLANGE ONTO HOT ENGINE.

NHTSA ID

11363130

Incident

Sep 21, 2020

Mileage

30,000 mi

IN 2014 THERE WAS A BMW RECALL ON THE FUEL PUMP AND AUX PUMP FLANGE AND THE PREVIOUS OWNER THAT OWNED THE BIKE REPLACED THE PUMP AND FLANGE AT THAT TIME. IT IS NOW ONLY 6 YEARS LATER; LAST YEAR I PAID MY LOCAL DEALER $382 TO REPLACE THE AUXILIARY FUEL PUMP AND GASKET IN MAY OF 2019, AND CURRENTLY (AUGUST 15, 2020) I AM PAYING $743 TO REPLACE THE MAIN FUEL PUMP AND FLANGE. MY QUESTIONS ARE: WHY DIDN'T THE 2014 RECALL SOLVE THE INITIAL PROBLEM WITH THE CRACKED AND LEAKING FLANGE AND IS THIS GOING TO BE A RE-OCCURRING PROBLEM EVERY 5 TO 6 YEARS? THE AUXILARY FUEL PUMP FLANGE AND THE MAIN FUEL PUMP FLANGE LEAK WAS NOTICIBLE WHEN I FIRST STARTED UP MY MOTORCYCLE. FUEL WAS STANDING / PRESENT ON TOP OF THE FUEL PUMP AND AUX. FUEL PUMP WHEN I STARTED THE BIKE. I BELIEVE THAT THE FLANGE AND THE QUICK CONNECT LINES ARE DEFECTIVE ON MY BIKE AND THAT THIS EVENT IS GOING TO KEEP RE-OCCURING EVERY 5 TO 6 YEARS. THERE HAS BEEN A RECALL ON CERTAIN BMW R1200GS MOTORCYCLES BY BMWUSA, BUT THE CUSTOMER SERVICE REPRESENTATIVE HAS INFORMED ME THAT MY VIN # IS NOT COVERED UNDER THE RECALL, BUT HE FAILED TO EXPLAIN WHY ITY WASN'T.

NHTSA ID

11351212

Incident

Aug 15, 2020

Mileage

34,283 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.