2008 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

THE FUEL TANK {FROM THE INSIDE OUT} AT THE FILLER HOLE HAS MASSIVE CORROSION RENDERING THE TANK USELESS. FUEL HAS THE ABILITY TO LEAK AN LEAK SUBSTANIALLY WHEN THE BIKE IS IN MOTION. FUME LEAKAGE READILY APPARENT AS WELL. PER THE CERTIFIED BMW MECHANIC AN THE SERVICE SUPERVISOR AND I AGREE THE FUEL TANK IS USELESS DUE TO MASSIVE PRE-MATURE CORROSION AN DEGRADATION OF THE TANK ITSELF. NOTE THAT THE MOTORCYCLE IS MAINTAINED UNDER A CARPORT AND ALWAYS OUT OF THE ELEMENTS. THIS IS A KNOWN FAILURE WITH BMW AND OF COURSE BMW HAS A HISTORY AS YALL WELL KNOW OF REFUSING TO STEP UP AN CORRECT DESIGN FAILURES UNLIKE OTHER COMPANIES SUCH AS TOYOTA. THE DISCOVERY WAS MADE WHEN THE WELL DOCUMENTED FUEL STRIP FAILURE OCCURRED AND THE 3RD STRIP WAS BEING INSTALLED. HOLES THE SIZE OF A POSTAGE STAMP AND "ROTTEN PAPER THIN" DEGRADATED METAL UNDERNEATH THE FILLER CAP IS EASILY TOTALLY DETAECTABLE. PER BMW THE TANK IS USELESS AN THERE IS NO FIX UNDER THAN REPLACEMENT- AND GET THIS PER THE BMW DEALER QUOTE - THIS PART IS OBSOLET- BMW IS NOT EVEN MAKING A REPLACEMENT FOR A 9 YR OLD BIKE. IT IS A FIRE HAZARD NOT ONLY TO THE MOTORCYCLE BUT TO THE OPERATOR AS WELL. IT IS CLEARLY A MANUFACTORS DEFECT WHICH BMW REFUSES TO ADDRESS. IT PRESENTS A SITUATION WHERE THE OPERATOR SHOULD NOT BE IN TRAFFIC DUE TO BEING A HAZARD TO HIMSELF, PASSENGERS, OR OTHER DRIVERS. LEAKING FUEL AN FUMES PRESENT A CLEAR HAZARD WHETHER IN MOTION OR EVEN AT IDLE. YALL MUST INVESTIGATE AN DEMAND BMW CORRECT THIS OUTRAGEOUS DESIGN FLAW, MATERIAL FAILURE IF FOR NO OTHER REASON THAN FROM A SAFETY VIEWPOINT. AGAIN, THIS IS A KNOWN ISSUE FOR R1200R'S AND THE 1200RT MODELS. REPLACE THE FUEL TANK IS THE SOLUTION TO THIS PROBLEM. PLEASE HOLD BMW ACCOUNTABLE FOR TOTALLY SUB-STANDARD WORKMANSHIP WHICH EQUATES TO POTENTIALLY FATAL CONSEQUENCES IF NOT RESOLVED. THK YOU

NHTSA ID

11013060

Incident

Jul 26, 2017

Mileage

54,000 mi

FUEL PUMP FLANGE LEAKING DUE TO CRACKING. BMW'S 1ST FACTORY ATTEMPT WAS TO PUT A "SIZING" RING ON FLANGE TO COMPRESS THE MICRO CRACKS WHICH OF COURSE WAS A JACKLEG APPROACH QUITE COMMON TO BMW MOTORCYCLES. EVENTUALLY WITH IN 1 YR FUEL STARTED MASSIVELY FLOWING DOWN ONTO HOT ENGINE MAKING THE BIKE A ROLLING FIREBALL POTENTIALLY.

NHTSA ID

11013059

Incident

Aug 15, 2016

Mileage

54,000 mi

TL* THE CONTACT OWNS A 2008 BMW R1200 R. WHILE DRIVING APPROXIMATELY 30 MPH, THE SERVICE BRAKE WARNING LIGHT ILLUMINATED. THE CONTACT LOST CONTROL OF THE VEHICLE WHEN THE BRAKE PEDAL WAS DEPRESSED. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE ABS MODULATOR FAILED AND NEEDED BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 16,210. UPDATED 5/18/15*CN THE CONSUMER STATED THE DEALER ADVISED THIS FAILURE WAS A COMMON PROBLEM ON THE THREE OR FOUR MODEL. THE CONSUMER BELIEVED THIS FAILURE SHOULD HAVE BEEN RECALLED. UPDATED 11/16/2015*JS

NHTSA ID

10705825

Incident

Dec 1, 2014

Mileage

16,210 mi

THE ABS PUMP FAILED DISABLING THE ANTI-LOCK SYSTEM. I WAS AT THE DEALER AND ANOTHER CYCLIST WAS ALSO THERE WITH HIS 2008 BMW R1200R WITH EXACTLY THE SAME ISSUE. APPARENTLY THESE ABS PUMPS ARE FAILING AT AN UNUSUAL RATE. IF THIS FAILURE OCCURRED WHILE RIDING IN INCLEMENT WEATHER IT COULD RESULT IN AN ACCIDENT.

NHTSA ID

10640340

Incident

Sep 12, 2014

Mileage

3,900 mi

ABS MODULE SUDDENLY QUIT, RENDERING THE ABS FUNCTION INOPERABLE. *JS

NHTSA ID

10598304

Incident

Jun 14, 2013

Mileage

40,000 mi

FUEL GAUGE FAILURE, SUDDENLY STOPPED WORKING AND READS EMPTY AT ALL TIMES. *TR

NHTSA ID

10536603

Incident

Aug 22, 2012

Mileage

6,800 mi

LOW FUEL WARNING LAMP DID NOT COME ON LEADING TO ME RUNNING OUT OF FUEL ON INTERSTATE HIGHWAY. FUEL GAUGE INDICATED APPROXIMATELY 1/4 TANK (3 BARS) BUT WAS INACCURATE. THIS IS AN UNSAFE CONDITION SINCE LOSS OF ENGINE POWER FROM RUNNING OUT OF FUEL CAN BE QUITE DANGEROUS ON A MOTORCYCLE. THE "FUEL STRIP" (PER BMW NOMENCLATURE) FAILS CAUSING FUEL GAUGE TO READ INACCURATELY AND RENDERING LOW FUEL WARNING LAMP INOPERATIVE. THIS IS A COMMON FAILURE ON MANY BMW MOTORCYCLE MODELS FROM 2005-2013. *TR

NHTSA ID

10499477

Incident

Apr 7, 2012

Mileage

4,900 mi

FROM THE DEALER'S REPAIR ORDER DESCRIPTION: "THE CUSTOMER REPORTS THE FUEL GAUGE READS LOW (LIGHT ON) WHEN FULL AND READS FULL WHEN EMPTY. ALSO THE RESIDUAL RANGE TO ZERO COUNTS DOWN FROM 253 TO THREE DASHES IN ABOUT THREE MILES AFTER EVERY FILL-UP." FUEL LEVEL SENDER PART 16147697815 REPLACED. *TR

NHTSA ID

10499342

Incident

Oct 13, 2009

Mileage

4,252 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.