2009 BMW R 1200 Gs Fuel system Problems

While attempting to pass a car on the highway, the engine suddenly lost power, forcing me into a perilous maneuver to reach the breakdown lane at highway speed. Following vehicle recovery and upon further inspection, I discovered that both plastic throttle body cam pulleys had broken in half, completely disabling throttle control. There were no warning lights or symptoms indicating this failure was imminent. In my research to fix the issue, I found that this problem is more common than I realized and poses a serious safety risk.

NHTSA ID

11628004

Incident

Sep 7, 2024

The contact owns a 2009 BMW R 1200 GS. The contact received notification of NHTSA Campaign Number: 20V471000 (Fuel System, Gasoline) however, the part to do the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The contact stated that after a short ride, the contact had made a stop and ran into a machine shop. The contact had parked (P) the vehicle and left it on. When the contact returned after a few minutes he saw that the vehicle had caught fire, the engine was still running. The location of the fire was from the gasoline tank and fuel pump assembly. The contact extinguished the fire using a large extinguisher available in the shop. The fire department was not called. The contact towed the vehicle to his motorcycle shop. The vehicle had not been repaired. The manufacturer was made aware of the issue. The failure mileage was approximately 36,000. Parts distribution disconnect.

NHTSA ID

11546013

Incident

Jun 6, 2023

Mileage

36,000 mi

The Fuel line connector at fuel pump started leaking and spraying fuel onto the hot engine and exhaust pipes causing the Motorcycle to catch on fire! the 2nd fuel pump the recall was not done yet. The best I can tell the owner did not get the 2nd recall or didn't forward it to the next owner. The person who was riding the motorcycle at the time escaped from being burned! He put it out the fire with a fire extinguisher, bike looks totaled, confirmed by the Dealer. I brought the motorcycle to the BMW dealership in Kansas City it has been inspected. but not by the manufacture yet. no police report was made. No warning lamps or messages or symptoms just burst into flames!

NHTSA ID

11534609

Incident

Jun 7, 2023

Hello I would like to open a case on a fire recall :VIN wb10313089zu47089 2009 BMW 1200gs Motorcycle , The motorcycle did start on fire casing much burn damage at the fuel line , needed the update fuel line and pump update. Rider was able to escape the flames and get a fire extinguisher and put out the fire ! I called BMW of north America , at first they said take it to the Dealer for a inspection it should be fixed at no charge. Made appointment for the 7-20-23 at BMW of Kansas City , Then they called me back said it was not covered because the last owner failed to take it in for the 2nd fire recall new updated fix so they are not responsible , I will keep you updated after the 20th of July , Thanks Randall McGowen , 40211 E Boswell Rd , Lone Jack, MO ( 816-699-1089) p.s. I am a retired GM master tech , seen many fire safety recalls , it defiantly sprayed fuel from the defective part to start the fire , luckily no one was burned!

NHTSA ID

11533136

Incident

Jun 7, 2023

I WAS DRIVING MY MOTORCYCLE WHEN I NOTICED A GAS LEAK COMING FROM THE FITTING WHERE THE FUEL LINE GOES INTO THE FUEL PUMP ON THE LEFT SIDE OF THE GAS TANK. THIS CAUSED GAS TO DRIP DIRECTLY ONTO THE LEFT SIDE EXHAUST MANIFOLD, WHICH COULD CAUSE A FIRE. IN THE PAST I HAD AN ISSUE WITH THE PLASTIC QUICK RELEASE FUEL LINE CRACKING WHERE IT SCREWED INTO THE FUEL PUMP (SAME LOCATION) AND DRIPPING GAS DIRECTLY ONTO THE LEFT EXHAUST MANIFOLD WHEN RIDING IT. I REPLACED THE PLASTIC QUICK RELEASE FUEL FITTING WITH A METAL ONE FROM THE SAME MANUFACTURER TO CORRECT THE ISSUE. CHECKING WITH OTHERS ONLINE, I HAVE DISCOVERED THAT BOTH OF THESE ISSUES ARE KNOWN, COMMON PROBLEMS ON THIS MODEL.

NHTSA ID

11173602

Incident

Jan 12, 2019

Mileage

10,700 mi

THE FUEL PUMP FLANGE CONNECTION IS CRACKED AND LEAKING FUEL. THERE ARE MULTIPLE PICTURES VIDEOS AND THREADS REGARDING RECALLS FOR THE EXACT SAME FUEL LEAK THAT I AM EXPERIENCING ON THE INTERNET. HOWEVER WHEN I CALLED BMW OF NORTH AMERICA THEY TELL ME THAT MY MOTORCYCLE IS NOT INCLUDED IN THE RECALL. CLEARLY THIS TYPE OF FUEL LEAK REPRESENTS A FIRE HAZARD AND DIRECT LIFE SAFETY ISSUE. MY QUESTION IS HOW CAN MY PARTICULAR MOTORCYCLE BE EXCLUDED FROM THIS WELL PUBLICIZED BMW RECALL SITUATION ?? FORTUNATELY I DISCOVERED THE FUEL LEAK IN MY GARAGE AND NOT WHILE GOING 70 MPH DOWN THE INTERSTATE

NHTSA ID

11083669

Incident

Apr 3, 2018

Mileage

23,000 mi

I WAS ACCELERATING ON THE ON-RAMP TO MERGE IN TO THE SLOW LANE WITH HEAVY TRAFFIC ON THE 80 NORTH BOUND HEADING HOME. I HAD JUST SHIFTED THE MOTORCYCLE IN TO 3RD GEAR WHEN IT LOST ALL POWER AND STARTED SLOWING DOWN. THE NEXT EXIT WAS NOT AVAILABLE TO REACH SAFELY AND MY ONLY OPTION WAS TO COAST INTO THE SIDE EMERGENCY LANE. AS I WAS INVESTIGATING THE ISSUE A SMALL PLASTIC PULLEY FORM THE LEFT SIDE THROTTLE-BODY FELL TO THE GROUND. I'M CURRENTLY CONTACTING BMW MOTORCYCLES AS THIS WAS A SERIOUS SAFETY ISSUE THAT PUT ME IN HARMS WAY. THIS PLASTIC PIECE IS UNDER CONSTANT TENSION AND IN MY OPINION SHOULD NEVER HAVE BEEN MAKE OF PLASTIC.

NHTSA ID

11003565

Incident

Jul 6, 2017

Mileage

28,650 mi

FUEL LEVEL SENSOR FAILURE TWICE. UNABLE TO DETERMINE LEVEL OF FUEL IN TAKE WHILE DRIVING AND STOPPED. INCREASED RISK OF RUNNING OUT OF GAS IN TRAFFIC.

NHTSA ID

10865667

Incident

Mar 15, 2016

Mileage

4,700 mi

ON FOUR DIFFERENT OCCASIONS, THE FUEL GAGE HAS FAILED. TWICE IT SHOWED FUEL WHILE RUNNING EMPTY, ONCE IN TRAFFIC. ON TWO OTHER OCCASIONS THE FUEL SCREEN HAS GONE BLANK. THREE TIMES THEY HAVE REPAIRED IT UNDER WARRANTY. IT HAS NOW HAPPENED AGAIN. I HAVE SINCE HEARD THEY RECALLED THERE CARS WITH THE SAME PROBLEM. THIS COULD BE A VERY DANGEROUS PROBLEM IN HEAVY TRAFFIC. *JS

NHTSA ID

10608789

Incident

Aug 19, 2011

Mileage

3,500 mi

FUEL GAUGE SUDDENLY FAILED AND GAVE INACCURATE READING. I HAVE HAD THE FUEL GAUGE REPLACED 4 TIMES, MOST RECENTLY LESS THAN ONE MONTH AGO, ALWAYS BY A BMW DEALER. THAT MOST RECENT GAUGE, INSTALLED 6/7/2014 BY THE DEALER, FAILED COMPLETELY, WITHOUT WARNING, ON 7/3/14 AFTER LESS THAN 250 MILES. THE FUEL GAUGE FAILURE CAN LEAD TO SUDDEN UNEXPECTED LOSS OF POWER, IF THE GAUGE INDICATES FUEL REMAINING, WHILE IN FACT THE TANK IS EMPTY. I AM ASTONISHED THE GOVERNMENT HAS NOT ORDERED BMW TO FIND A RELIABLE FIX THIS. ANECDOTAL INDICATIONS ARE THOUSANDS OF GAUGES HAVE FAILED, OVER APPROXIMATELY A FIVE MODEL YEAR PERIOD THE DEFECTIVE DESIGN WAS USED. *TR

NHTSA ID

10608335

Incident

Sep 26, 2013

Mileage

22,520 mi

TRAVELING APPROX 60 MPH DURING RUSH HOUR IN MIDDLE LANE OF THREE LANE DIVIDED HIGHWAY. FUEL GAUGE SHOWED TWO BARS AND DISPLAY INDICATED APPROX 60 MILES OF RANGE LEFT. ENGINE SUDDENLY LOST POWER. I WAS ABLE TO GET TO RIGHT SHOULDER WHEN ENGINE DIED AND WOULD NOT RESTART. WAS ABLE TO PUSH APPROX 1/4 MILE TO EXIT RAMP AND THEN TO FUEL STATION. FUEL TANK WAS EMPTY. FUEL GAUGE NEVER SHOWED EMPTY NOR DID LOW FUEL LIGHT COME ON. *TR

NHTSA ID

10550300

Incident

Oct 30, 2013

Mileage

20,434 mi

BIKE FUEL METER DOES NOT FUNCTION. REPLACED UNDER WARRANTY 8/12/11 AND 8/10/13. FUEL METER RELIES ON SENSOR STRIP INSIDE FUEL TANK. SENSOR STRIP FAILS WITHOUT WARNING. OBVIOUS SAFETY ISSUE IF FAILURE CAUSES BIKE TO UNKNOWINGLY AND SUDDENLY RUN OUT OF FUEL WHILE MOVING. *TR

NHTSA ID

10534664

Incident

Aug 9, 2013

Mileage

15,329 mi

THE FUEL GAUGE STOPPED WORKING AND THERE WAS A YELLOW WARNING LIGHT APPEARED ON THE DISPLAY. PRIOR TO THE OUTRIGHT FAILURE, THE GAUGE HAD OCCASIONALLY SHOWN A FALSE VALUE, SHOWING TOO MUCH FUEL FOR THE MILES COVERED, AND THEN SUDDENLY IT WOULD DROP TO THE CORRECT VALUE, INDICATING ALMOST ZERO FUEL LEFT. THE GAUGE NOW SHOWS NO FUEL LEVEL AT ALL CONSTANTLY. THE MOTORCYCLE WAS JUST OUT OF WARRANTY WHEN THIS OCCURRED. WHEN YOU PURCHASE A NEARLY $20K MOTORCYCLE, YOU EXPECT SIMPLE THINGS LIKE A FUEL GAUGE SENSOR TO WORK RELIABLY. BMW HAS FAILED TREMENDOUSLY IN THIS RESPECT. *TR

NHTSA ID

10533695

Incident

Aug 30, 2011

Mileage

9,800 mi

WHILE OPERATING THE MOTORCYCLE AT APPROXIMATELY 50 MPH IT SUDDENLY STOPPED RUNNING. AFTER COASTING TO A STOP I OBSERVED FUEL STEADILY LEAKING FROM THE FUEL PUMP, DOWN THE FRONT OF THE ENGINE AND ONTO THE HOT EXHAUST. I HAD TO LEAN THE BIKE AGAINST A FENCE POST IN ORDER TO GET FUEL TO FLOW AWAY FROM HOT EXHAUST AND PREVENT FIRE. UPON LATER EXAMINATION I FOUND THAT THE FUEL WAS LEAKING FROM MULTIPLE SMALL CRACKS IN A FLANGE LOCATED AT THE TOP TO THE FUEL PUMP AND WHERE THE FUEL LINE IS ATTACHED. THE PLASTIC FLANGE APPEARS TO HAVE FAILED LEADING TO THE LEAK. *TR

NHTSA ID

10508150

Incident

Jun 10, 2012

Mileage

5,200 mi

FUEL GAUGE FREQUENTLY INDICATES PLENTY OF FUEL IN TANK WHEN TANK RUNS EMPTY. GAUGE WILL ALSO OCCASIONALLY SHOW EMPTY WHEN SEVERAL GALLONS OF FUEL IN TANKS. *TR ## VIN FAILED ##

NHTSA ID

10504958

Incident

Mar 26, 2012

Mileage

12,000 mi

TL* THE CONTACT OWNS A 2009 BMW R 1200 GS MOTORCYCLE. THE CONTACT STATED THAT THE TRIANGLE WARNING LIGHT ILLUMINATED. THE VEHICLE ONLY HAD ONE WARNING LIGHT AND THE CONTACT WAS CONCERNED THAT IF ANY OTHER SYSTEM ON THE MOTORCYCLE FAILED, HE WOULD NOT BE AWARE OF THE PARTICULAR FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER WHO ADVISED THAT THE FUEL LEVEL SENSOR FAILED. THE VEHICLE WAS REPAIRED BY REPLACING THE SENSOR. THE FAILURE RECURRED AND WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, HOWEVER NO ASSISTANCE WAS PROVIDED. THE CURRENT MILEAGE WAS 1,856. THE FAILURE MILEAGE WAS 1,500.

NHTSA ID

10471237

Incident

May 1, 2011

Mileage

1,500 mi

BMW MOTORCYCLES FUEL GAUGE WITH "ELECTRONIC FUEL STRIP" FAIL RESULTING IN SAME CONDITION AS THEIR CAR RECALL SHOWN BELOW! DANGEROUS CONDITION RESULTS. (POST 2010 MODELS CHANGED TO FLOAT TYPE SYSTEM). SUMMARY: BMW IS RECALLING CERTAIN 2010 AND 2011 5-SERIES AND 5-SERIES GRAN TURISMO PASSENGER VEHICLES MANUFACTURED FROM JANUARY 12 THROUGH JULY 1, 2010. THE VEHICLE'S FUEL LEVEL SENSOR WITHIN THE FUEL TANK CAN BECOME WEDGED AGAINST THE TANK. CONSEQUENCE: IF THIS OCCURS, THE FUEL GAUGE IN THE INSTRUMENT CLUSTER WOULD DISPLAY A LARGER AMOUNT OF FUEL THAN WAS ACTUALLY IN THE TANK. AS A RESULT, IF THE TANK BECAME EMPTY, THE VEHICLE COULD STALL INCREASING THE RISK OF A CRASH. *TR

NHTSA ID

10461180

Incident

Jun 10, 2010

Mileage

19,404 mi

2009 BMW R1200GS FUEL STRIP FAILURE. *TR

NHTSA ID

10406900

Incident

Jan 15, 2011

Mileage

9,000 mi

RIDING MOTORCYCLE WITH FUEL GAUGE DISPLAYING 3/4 FULL TANK AND THEN SUDDENLY THE BIKE RAN OUT OF FUEL WHILE DRIVING DOWN THE ROAD. TOOK MOTORCYCLE INTO DEALER AND THE FUEL STRIP SENSOR WAS REPLACED UNDER WARRANTY, DEALER KEPT OLD PART. THE FUEL SENSOR HAS SUBSEQUENTLY FAIL TWO MORE TIMES CAUSING A STALLING OF THE ENGINE WHILE RIDING ALONG A ROAD. DEALER HAS REPLACED FUEL SENSOR STRIP THREE TIMES. *TR

NHTSA ID

10396891

Incident

Mar 1, 2009

Mileage

100 mi

FUEL GAUGE ON MY 2009 BMW R1200GS MOTORCYCLE WAS SHOWING I HAD APPROXIMATELY 1/3 OF A TANK OF FUEL WHEN I RAN OUT OF GAS. I WAS TRAVELING ON A FREEWAY DURING RUSH HOUR TRAFFIC. I WAS ONLY GOING ABOUT 15MPH WHEN THIS HAPPENED BUT WAS FORCED TO GET OFF THE BIKE AND PUSH IT TO THE FAST LANE SHOULDER. I WAS ABLE TO GET THE BIKE RESTARTED BY LEANING IT OVER AS FAR AS I COULD TO THE LEFT WHICH LET SOME ADDITIONAL FUEL GO FROM THE RIGHT TO THE LEFT SIDE OF THE TANK. I FEEL THIS WAS A VERY DANGEROUS SITUATION. APPARENTLY THIS IS A WELL KNOW ISSUE BY BMW OF NORTH AMERICA AS IT SEEMS TO BE HAPPENING TO MANY PEOPLE WHO OWN BMW MOTORCYCLES. I HAVE HAD MY MOTORCYCLE IN TO THE SHOP THREE TIMES AND IT STILL IS NOT FIXED. I WILL GO IN FOR A FOURTH TIME TO SEE IF THEY CAN MAKE IT WORK PROPERLY AGAIN. *TR

NHTSA ID

10396871

Incident

Nov 24, 2010

Mileage

6,200 mi