2007 BMW R 1200 R

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

DRIVING ON THE HIGHWAY WITH FUEL INDICATOR SHOWING FULL TANK OF GAS. SUDDEN LOSS OF POWER DUE TO FUEL TANK RUNNING TO EMPTY ON ACCOUNT OF INCORRECT INDICATOR.

NHTSA ID

11046635

Incident

Sep 15, 2017

Mileage

40,000 mi

RIDING ON THE HIGHWAY (LEFT LANE) AT 65 MPH THE FUEL GAUGE SHOWED SLIGHTLY LESS THAN 1/4 TANK, THE COMPUTER SHOWED 50+ MILES OF GAS LEFT. THE ENGINE QUIT AND I HAD TO SLOWLY DRIFT ACROSS 3 LANES OF TRAFFIC TO GET TO THE SHOULDER. THE TANK WAS EMPTY.

NHTSA ID

11030086

Incident

Sep 12, 2017

Mileage

98,000 mi

TL* THE CONTACT OWNS A 2007 BMW 1200RT MOTORCYCLE. THE CONTACT STATED THAT THE FUEL GAUGE WOULD CONSTANTLY DISPLAY ERRONEOUS FUEL READINGS. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED WITH A FRACTURED FUEL PUMP WHICH NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURE WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 2,000 AND THE CURRENT MILEAGE WAS 28,000. KMJ

NHTSA ID

10587386

Incident

May 16, 2007

Mileage

2,000 mi

BRAKE FAILURE LIGHT CAME ON WHILE ON AN OUT OF STATE TRIP. AFTER GETTING HOME AND DOING SOME RESEARCH I HAVE FOUND THIS IS A PROBLEM CAUSED BY FAULTY BRUSHES IN THE ELECTRICAL MOTOR ON THE ABS PUMP. READING MANY ONLINE MOTORCYCLE FORUMS THIS APPEARS TO BE A KNOWN ISSUE ON ALL BMW R SERIES MOTORCYCLES. *TR

NHTSA ID

10558431

Incident

Aug 11, 2013

Mileage

66,000 mi

FUEL GAUGE FAILED RESULTING IN RUNNING OUT OF FUEL WHEN AT SPEED ON A HIGHWAY, CREATING AN UNSAFE CONDITION. BEING STALLED ON A MOTORCYCLE IN THE MIDDLE OF HEAVY TRAFFIC IS UNSAFE. THIS HAS HAPPENED REPEATEDLY - THIS IS THE 6TH REPLACEMENT FUEL STRIP ON THIS MOTORCYCLE. BMW CLAIMS THERE ISN'T A PROBLEM AND BLAMES US FUEL IF THERE IS A PROBLEM. *TR

NHTSA ID

10501125

Incident

Feb 25, 2013

Mileage

62,395 mi

FUEL GAUGE STOPPED RESPONDING, LEADING TO RUNNING OUT OF FUEL WHILE MOVING. THIS IS A COMMON FAILURE ON MANY BIKE MODELS FROM BMW FROM 2005-2013. I HAVE HAD THIS HAPPEN 5 TIMES SO FAR, AND EACH TIME THE FUEL LEVEL MEASURING STRIP IN THE FUEL TANK WAS REPLACED. THIS IS AN UNSAFE CONDITION SINCE LOSS OF ENGINE POWER FROM RUNNING OUT OF FUEL CAN BE QUITE DANGEROUS ON A MOTORCYCLE. *TR

NHTSA ID

10499319

Incident

Feb 1, 2013

Mileage

30,000 mi

THIS IS THE WELL-KNOWN BMW MOTORCYCLE FUEL STRIP SENSOR PROBLEM. THE GAS GAUGE SENSOR GOES DEFECTIVE AND WILL READ THAT YOU HAVE MORE GAS THAN YOU ACTUALLY DO, THUS RUNNING OUT OF GAS IN DANGEROUS SITUATIONS (FREEWAY, BAD PART OF CITIES, ETC.) MANY, MANY BMW MOTORCYCLE OWNERS REPORT THIS, BUT IF BIKE IS OUT OF WARRANTY IT'S A $300 REPAIR ITEM THAT BMW WILL NOT HONOR. *TR

NHTSA ID

10447943

Incident

Dec 5, 2011

Mileage

17,323 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.

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.

One of the following situations can occur when connecting to BN2000 motorcycles: 1. The installed control units cannot be found when reading out with ISTA. 2. Control units initially communicate after connecting to the vehicle, but communication later stops.

BMW Motorrad has ascertained that in isolated cases the fuse for the voltage regulator is not correctly secured in the holder by the threaded fasteners.