2006 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

TL* THE CONTACT OWNS A 2006 BMW R1200 RT. WHILE DRIVING 55 MPH, THE CONTACT SMELLED FUEL COMING FROM THE FUEL PUMP. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT STOPPED THE VEHICLE AND NOTICED FUEL LEAKING OVER THE ENGINE. THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM, GASOLINE). THE CONTACT CALLED BMW MOTORCYCLES MCDONOUGH (LOCATED AT 755 INDUSTRIAL BLVD, MCDONOUGH, GA 30253, (770) 957-7404) AND INFORMED THEM OF THE FAILURE. THE MOTORCYCLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 41,109. *LN CONSUMER STATED THIS ISSUE WAS ADDRESSED ONCE IN RECALL 13V617 IN 2014. REPAIR HISTORY INDICATES MY BIKE WAS CHECKED FOR THIS ISSUE BUT THERE IS NO INFORMATION ON WHETHER REPAIRS WERE PERFORMED. GIVEN THE INFORMATION IN THE TECHNICAL DOCUMENT, EITHER THE PUMP WAS REPLACED ENTIRELY OR THERE WAS NOTHING DONE. NO METAL REINFORCING RING WAS PLACED ON THE FUEL PUMP, SO EITHER THE PUMP WAS REPLACED WITH ANOTHER FAULTY PUMP OR NO REPAIRS WERE MADE. THIS RECALL WAS NOT ADDRESSED ON MY BIKE EVEN THOUGH THE BIKE WAS CHECKED. I AM HAVING THE EXACT ISSUE MENTIONED FOR SIEMENS FUEL PUMPS IN BMW MOTORCYCLES UNDER THE RECALL. PHOTOS, FUEL LEAK NHTSA INVESTIGATION, AND 2006 BMW REPAIR HISTORY ATTACHED.*JB

NHTSA ID

11267990

Incident

Oct 2, 2019

Mileage

41,109 mi

THE FUEL STRIP THAT READS GASOLINE LEVEL IS DEFECTIVE. FIRST REPAIR LASTED LESS THAN 200 MILES. RECENT REPLACEMENT FAILED AS I MADE THE TURN OUT OF THE DEALERSHIP FROM THE LAST REPAIR.

NHTSA ID

11001490

Incident

Jun 23, 2017

WHILE DRIVING SOUTHBOUND ON I-79 NEAR PITTSBURGH AT APPROXIMATELY 70 MPH THE REAR UNIVERSAL JOINT LET GO. THIS CAUSED THE MOTORCYCLE REAR WHEEL TO INTERMITTENTLY LOCK UP AND RELEASE. THE UNIVERSAL HAS NO MEANS TO LUBRICATE IT AND NO NOISE OR VIBRATION WAS HEARD OR FELT BEFORE FAILURE.

NHTSA ID

10885480

Incident

Jul 17, 2016

Mileage

104,473 mi

AS I WAS DECELERATING FOR A TURN I FELT A SHUDDER AND HEARD A GRINDING NOISE AND LOST REAR WHEEL BRAKING. I PULLED TO THE SIDE OF THE ROAD AND UPON EXAMINATION OF THE REAR WHEEL DISCOVERED THAT THE REAR BRAKE DISC WAS SEPARATED FROM THE BRAKE MOUNTING FLANGE. EACH OF THE FIVE MOUNTING HOLES HAD FAILED AND ALLOWED THE DISC TO SEPARATE. THE REAR WHEEL IS ALSO BOLTED TO THIS FLANGE. SUBSEQUENT RESEARCH HAS REVEALED THAT THIS IS NOT AN UNCOMMON PROBLEM. MY FEELING IS THAT THIS TYPE FAILURE COULD CAUSE A CATASTROPHIC FAILURE SINCE IT INVOLVES A FAILURE AT SPEED AND RELATES TO THE REAR WHEEL AND REAR BRAKE MOUNTING FLANGE. DEFINITELY A SAFETY ISSUE! *TR

NHTSA ID

10672199

Incident

Dec 27, 2014

Mileage

74,300 mi

WHILE CHANGING MY REAR BRAKES, I NOTICED THAT THE REAR SPACER FLANGE THAT ATTACHES THE WHEEL TO THE ROTOR IS CRACKED IN 3 DIFFERENT MOUNTING AREAS. I DO NOT RIDE OFF ROAD OR OTHERWISE ABUSE THE BIKE. *TR

NHTSA ID

10639539

Incident

Sep 26, 2014

Mileage

43,000 mi

AS I WAS TRAVELING AT 70 MPH ON THE HIGHWAY I FELT MY MOTORCYCLE ALL OF A SUDDEN WOBBLE AND LOST CONTROL. I STRUGGLE TO REGAIN CONTROL OF THE MOTORCYCLE AND WAS ABLE TO BRING THE MOTORCYCLE TO A STOP BY THE SHOULDER OF THE ROAD. IT APPEARED MY FINAL DRIVE (TRANSMISSION ) HAD FAILED PREMATURELY. THERE WERE OIL FROM THE FINAL DRIVE SPLATTERED ALL OVER MY REAR WHEEL. THIS WAS A FREIGHTING EXPERIENCE AND COULD HAVE RESULTANT IN SERIOUS INJURY TO ME BECAUSE OF A PREMATURE FAILURE OF THE FINAL DRIVE. *TR

NHTSA ID

10637145

Incident

Sep 14, 2014

Mileage

37,700 mi

FUEL LEAK: THE PLASTIC AROUND THE FUEL PUMP OUTPUT FITTING IS CRACKED AND LEAKING. MY LEFT LEG WAS COVERED IN GASOLINE AS WELL AS MY LEFT FAIRING. *TR

NHTSA ID

10625854

Incident

Aug 12, 2014

Mileage

45,256 mi

I WAS CRUISING ALONG ON MY BMW R1200 RT AT THE 70MPH SPEED LIMIT WHEN ALL THE SUDDEN THE BRAKE FAILURE LIGHT FLASHED REPEATEDLY ON THE DASH, ALONG WITH A RED WARNING TRIANGLE. I IMMEDIATELY LOOK FOR THE NEXT EXIT, BUT BEFORE I GET TO THE EXIT, I ENCOUNTER A HEAVY RAIN. WHEN I TRY TO SLOW THE BIKE, THE BRAKES ARE NUMB, AND VERY DIFFICULT TO PRESS. THIS CAUSES AN IMMEDIATE PANIC, BUT I'M ABLE TO SLOW THE BIKE AFTER A VERY LONG INTERVAL. I PARK THE BIKE AND READ THE OWNERS MANUAL ABOUT THE FAILURE. IT IS DESCRIBED AS A SERIOUS FAILURE WHICH WILL CAUSE THE SERVO ASSIST TO BE DEACTIVATED, BUT THE BIKE IS STILL RIDEABLE. SINCE I WAS OVER 300 MILES FROM HOME, I ATTEMPTED TO MANAGE THE PROBLEM AS THE MANUAL RECOMMENDED. THE BIKE IS BASICALLY UNRIDEABLE AND NOT CONTROLLABLE WHEN THIS ERROR APPEARS. THERE IS NO WAY TO CONTROL YOUR STOP, AND THIS IS NOTHING LIKE JUST LOSING YOUR ABS, AND HAVING TO RESORT TO REGULAR BRAKES. THIS IS LIKE HAVING ABOUT 30% OF YOUR BRAKES AVAILABLE! WHICH IS TERRIFYING. I DON'T KNOW WHY THIS SYSTEM IS DESIGNED THIS WAY,OR WHY BMW WOULD SUGGEST IT'S OKAY TO CONTINUE TO RIDE IN THIS MANNER. I FELT LIKE MY CHANCES OF BEING IN AN ACCIDENT WERE INCREASED BY 120%. THIS BRAKING SYSTEM IS DANGEROUS. SO MUCH SO, THAT I FOUND OUT THAT BMW DISCONTINUED ITS USE AFTER THE 2006 PRODUCTION AND WENT WITH A TOTALLY NEW SYSTEM. THIS SYSTEM WAS ONLY USED FOR 2 YEARS ON THE R1200RT. I WOULD LOVE TO KNOW WHY THIS SYSTEM WASN'T RECALLED, AND WHAT BMW KNOWS ABOUT THE FAILURE POTENTIAL. MAYBE THAT'S WHY THEY DISCONTINUED IT. I FELT MY LIFE WAS PUT IN DANGER BY RIDING THIS MOTORCYCLE. BMW SHOULD BE HELD ACCOUNTABLE. *TR

NHTSA ID

10618002

Incident

Jun 27, 2014

Mileage

7,806 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.

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