2005 BMW R 1200 RT

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

2005 BMW r1200rt that I have owned since 2016 with little to no issue. Leak from winter storage in the front left side of the engine. It matches a thread of a cracked fuel pump. With your site they submitted the problem under JBN1-18051. Also under a complaint number 10428629. I wish to know if it is a issue that is a recall or something I can submit for BMW to take care of, or if I will need to get fixed myself. I saw that riding with it can result in fuel landing on the ride during transit making it dangerous to ride.

NHTSA ID

11513782

Incident

Mar 24, 2023

The contact owns a 2005 BMW R 1200 RT. The contact stated while starting the motorcycle and it began to stall. The contact stated no warning light was illuminated. The motorcycle was not drivable. The motorcycle was towed to an independent mechanic and the contact was informed that the fuel pump needed to be replaced. The motorcycle was repaired. The contact stated that on 7/2021, he noticed fuel leaking from the fuel pump onto the engine. The contact called the local dealer and made them aware of the failure. The motorcycle was not repaired but was pending repairs. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 13V617000 (Fuel System, Gasoline) however, the VIN was not included. The manufacturer had not been informed of the failure. The failure mileage was approximately 52,000.

NHTSA ID

11434688

Incident

May 1, 2016

Mileage

52,000 mi

CRACKED THROTTLE CONTROL CABLE CONNECTIONS TO BOTH THROTTLE BODY THROTTLE CONTROL SHAFTS. IF THIS FAILS, THE THROTTLES RETURN TO IDLE WITHOUT ANY ABILITY TO ACCELERATE. THIS TYPE OF FAILURE HAS BEEN REPORTED BY OTHER OWNERS OF THE SAME MODEL. I NEED TO REPAIR PRIOR TO TRAVEL USE TO AVOID THIS SITUATION.

NHTSA ID

11413715

Incident

Apr 24, 2021

Mileage

32,000 mi

TL* THE CONTACT OWNS A 2005 BMW R1200. WHEN THE CONTACT ATTEMPTED TO START THE CYCLE, IT FAILED AND FUEL WAS LEAKING FROM THE FRONT. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE LOCAL DEALER (HAP'S CYCLE SALES, INC, 2530 17TH ST, SARASOTA, FL, 34234) WAS CONTACTED AT 941-365-3443. THE CONTACT TOOK THE FUEL PUMP APART AND CONFIRMED THROUGH THE PHONE WITH THE DEALER THAT THE COUPLING TO THE FUEL PUMP OF THE FLANGED HAD FRACTURED AND NEEDED TO BE REPLACED. THE CYCLE WAS NOT DIAGNOSED OR REPAIRED BY THE DEALER OR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS CONTACTED AND STATED THAT THERE WAS NO RECALL ON THE CYCLE. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM). THE FAILURE MILEAGE WAS APPROXIMATELY 17,120.

NHTSA ID

11046223

Incident

Nov 8, 2017

Mileage

17,120 mi

DRIVE SHAFT U-JOINT FAILURE RIDING ON INTERSTATE 5. BIKE STARTED TO VIBRATE AND WHEN CLUTCH WAS DEPRESSED, VIBRATION STOPPED. RELEASED CLUTCH AND VIBRATION STARTED AGAIN. DEPRESSED CLUTCH AGAIN AND PULLED TO SIDE OF THE ROAD BEFORE DRIVE SHAFT LOCKED UP. PULLED BACK REAR BOOT ON FINAL DRIVE AND THERE WAS SMOKE COMING OUT OF THE SWING ARM SHAFT. BMW DEALER DIAGNOSED IT AS A FAILED U-JOINT BUT COULD NOT REPAIR UNLESS THEY REMOVED TRANSMISSION TO REMOVE U-JOINT STUCK ON TRANSMISSION SPLINE. PRICE FOR DRIVE SHAFT ALONE WAS $1,100 DOLLARS PLUS LABOR TO REMOVE TRANSMISSION.

NHTSA ID

10914193

Incident

Sep 30, 2016

Mileage

110,000 mi

WHILE PULLING AWAY FROM A STOP SIGN THE MOTORCYCLE INCREASED SPEED AND RPM'S IN EXCESS OF THE AMOUNT OF THROTTLE I WAS TWISTING. I IMMEDIATELY PULLED IN THE CLUTCH AND RELEASED THE THROTTLE. THE RPM'S CONTINUED TO CLIMB OVER 4000 AND THE ENGINE SUSTAINED THIS LEVEL. THE MOTORCYCLE WOULD ONLY RETURN TO A NORMAL IDLE LEVEL (1100 RPM) IF I FORCED THE THROTTLE CLOSED (FORWARD TWISTING MOTION). THIS MATTER COULD HAVE BEEN VERY DANGEROUS AND LIFE THREATENING. I DELIVERED THE MOTORCYCLE TO THE BMW DEALER TO HAVE THE MATTER DIAGNOSED. THE BMW MECHANIC ADVISED THAT THE THROTTLE CABLE PULLEY'S HAD BROKEN ON BOTH THROTTLE BOTH THROTTLE BODIES. I WAS FURTHER ADVISED THAT THESE PULLEY'S ARE MADE OF A MOLDED PLASTIC MATERIAL AND THAT THIS MATERIAL BROKE. THE MECHANIC HAS ALSO INFORMED ME THAT THESE PARTS (ALTHOUGH EXTERNAL ON THE THROTTLE BODIES) ARE NOT REPLACEABLE. THE ENTIRE THROTTLE BODIES MUST BE REPLACED. I BELIEVE THAT BMW SHOULD BE RECALL THESE ITEMS FOR THE OBVIOUS SAFETY RISKS RELATED TO THEIR FAILURE.

NHTSA ID

10838801

Incident

Feb 19, 2016

Mileage

169,500 mi

MOTORCYCLE FUEL GAUGE NOT WORKING. ALWAYS SHOWING EMPTY. TOOK MOTORCYCLE TO DEALER AND HAD FUEL LEVEL SENSOR REPLACED. MOTORCYCLE FUEL GAUGE NOW SHOWING FULL ALL THE TIME UNTIL ONE RECENT FUEL FILL UP IT WENT BACK TO SHOWING EMPTY. I HAD BEEN USING THE TRIP METER TO JUDGE FUEL LEVEL FILLING THE TANK AT 250 MILES. ON THE DATE OF THIS INCIDENT, IN THE MIDDLE OF HEAVY TRAFFIC, I RAN OUT OF FUEL AT APPROX. 200 MILES. I MANAGED TO GET OFF OF THE ROAD WITHOUT GETTING RUN OVER. I HAVE CALLED BMW NORTH AMERICA AND WAS TOLD THAT THE FUEL SENSOR PROBLEM WAS NOT KNOWN ABOUT BUT THAT SHE WOULD TAKE MY COMPLAINT. I HAVE READ MANY, MANY......MANY COMPLAINTS FROM BMW OWNERS ABOUT THIS PROBLEM. I WAS TOLD BY A DEALER THAT BMW HAD EXTENDED THE WARRANTY TO COVER THIS PROBLEM FOR 12 YEARS BUT BMW HAD NOT FIXED THE PROBLEM. THEY WOULD JUST CONTINUE TO REPLACE THE SENSORS UNTIL THE 12 YEARS PASSED. THIS IS A SERIOUS PROBLEM EVIDENTLY NOT TAKEN SERIOUSLY BY BMW. IN THE LATTER PART OF 2010 THEY WENT BACK TO A FLOAT STYLE SENSOR BUT HAVE MADE NO ATTEMPT TO FIX THE PROBLEM CREATED BY A POSSIBLE MATERIAL DEFECT AND/OR POOR DESIGN IN THEIR FUEL LEVEL SENSORS INSTALLED IN MODEL YEARS 2005 THROUGH MIDDLE OF 2010. *TR

NHTSA ID

10628565

Incident

Aug 25, 2014

Mileage

22,000 mi

REPORT RECEIPT DATE: DEC 12, 2013 NHTSA CAMPAIGN NUMBER: 13V617000 COMPONENT(S): FUEL SYSTEM, GASOLINE MY COMPLAINT : RECALL LETTER NOT RECEIVED FROM BMW. *TR

NHTSA ID

10588441

Incident

May 14, 2014

Mileage

42,300 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.

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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.