2006 BMW R 1200 RT Fuel system Problems

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

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

IN-TANK FUEL PUMP LEAKS FUEL AT THREADED CONNECTION TO OUTLET QUICK-RELEASE FITTING. I PURCHASED AND INSTALLED A REINFORCEMENT CLAMP MADE BY A THIRD-PARTY SUPPLIER AND REINSTALLED THE QUICK-RELEASE FITTING WITH A FUEL-RESISTANT THREAD SEALANT, BUT THE FITTING STILL LEAKS. I'LL TRY ADHESIVE INSTEAD, ON THE ADVICE OF OTHERS WITH THE SAME PROBLEM. FUEL LEAKS ARE NOT ACCEPTABLE ON ANY VEHICLE, PARTICULARLY NOT ON A SUPPOSEDLY HIGH-QUALITY MOTORCYCLE. *TR

NHTSA ID

10550550

Incident

Oct 30, 2013

Mileage

9,678 mi

I SMELLED FUEL (ON AND OFF) ON THE HIGHWAY ON THE WAY TO WORK. WHEN I CAME TO MY PARKING SPACE, THEN I REALLY SMELLED IT. WHEN I LEANED THE BIKE TO PUT IS ON THE SIDE STAND SOME FUEL DRIPPED OUT FROM UNDER THE COWLING, RIGHT BY THE EXHAUST PIPE. AFTER WORK, IN THE PARKING LOT, I DISASSEMBLED THE COWLING AND FOUND THAT THE BASE OF THE FUEL PUMP ASSEMBLY PACKAGE WHERE THE FUEL LINE CONNECTOR FITTING GOES INTO, WAS CRACKED, (NOT ENOUGH PLASTIC AROUND THE FITTING). I CALLED THE DEALER AND HE KNEW EXACTLY WHAT I WAS REFERRING TO, AND WAS TOLD THE PART WAS $550 BECAUSE IT INCLUDED THE FUEL PUMP (WHICH I DON'T NEED). I DECIDED THAT I WOULD NOT BUY ANOTHER DEFECTIVELY DESIGNED PIECE, SO I GOT A CLAMP AND PUT IT OVER THE CRACKED PART, AND EPOXIED IT. MAKING IT A BETTER DESIGN. THE NEXT DAY, I ALSO WAS TOLD THAT THE NEW PIECE FROM BMW HAS THE SAME SOLUTION TO THE PROBLEM, A STEEL BAND. I DON'T KNOW IF THEIRS IS STAINLESS STEEL LIKE MINE. AT FIRST, I WOULD HAVE SETTLED FOR JUST THE PART I NEEDED, BUT TO BE SOLD THE SAME CRAP PLUS A PART I DIDN'T NEED, I WASN'T GOING TO DO IT. AT THE URGING OF ANOTHER DEALER I CALLED BMW CUSTOMER SERVICE AND THEY SAID THEY DIDN'T CARE ABOUT MY PROBLEM, IN A PROFESSIONAL WAY OF COARSE. I TRY NOT TO PANIC ABOUT SAFETY ISSUES (I AM AN INSPECTOR OF EQUIPMENT IN ANOTHER LINE OF WORK). HOWEVER, THEIR LACK OF CORRECTIVE BACKING OF A BADLY DESIGNED PART CAUSED ME TO FILE THIS COMPLAINT. IT IS AT IT'S CORE A SAFETY ISSUE. *TR

NHTSA ID

10550138

Incident

Oct 25, 2013

Mileage

17,125 mi

WHILE RIDING MOTORCYCLE NOTED FUEL SMELL AND DISCOVERED LEAKING FUEL FROM CRACKS IN THE FUEL PUMP ASSEMBLY TOP PLATE WHERE THE PLASTIC HIGH PRESSURE LINE QUICK DISCONNECT FITTING SCREWS IN TO THE TAPERED PIPE THREADS OF THE PLASTIC PLATE. NOTED EVIDENCE OF FUEL LEAKAGE POOLING WITH POTENTIAL OF DRIPPING ONTO HOT EXHAUST COMPONENTS. IF FUEL WERE TO BE IGNITED THERE WOULD LIKELY BE A CATASTROPHIC FIRE AND POTENTIAL CRASH. THERE IS ALSO THE POSSIBILITY OF LOSS OF TRACTION FOR THE REAR TIRE DUE TO LEAKAGE ON THE GROUND, ALSO POTENTIALLY LEADING TO A CRASH. I BELIEVE THIS IS A SERIOUS DESIGN SPECIFICATION FLAW THAT MAY OCCUR ON ALL THE MOTORCYCLES SIMILARLY EQUIPPED. I ALSO BELIEVE THIS WARRANTS IMMEDIATE ACTION BY BMW, BOTH FOR MOTORCYCLES THAT HAVE YET TO FAIL, AND FOR THOSE THAT HAVE FAILED AND HAVE BEEN REPAIRED BY THE OWNERS. *TR

NHTSA ID

10546949

Incident

Oct 4, 2013

Mileage

57,012 mi

CRACKED FUEL PUMP FLANGE,LEAKING GAS AND SPRAYING ON RIDER. THIS IS THE FOURTH BMW BIKE I HAVE OWNED AND HAVE HAD NO PREVIOUS PROBLEMS. *TR

NHTSA ID

10543576

Incident

Sep 13, 2013

Mileage

42,000 mi

GAS LEAKING FROM LEFT SIDE FAIRING AFTER RIDING WITH SMALL SPILL OF GAS ON GARAGE FLOOR. TAKEN TO MORTONS BMW DEALER TODAY WHERE DEFECTIVE O-RING AND CRACKS IN FUEL PUMP FLANGE WERE NOTED. PRIOR # JBN1-18051. *TR

NHTSA ID

10534549

Incident

Aug 3, 2013

Mileage

20,580 mi

FUEL SMELL ON CLOTHING AND LEAKING FUEL FOUND DRIPPING ON HOT EXHAUST DURING STOP AT GAS STATION TO REFUEL. IMMEDIATELY PUSH MOTORCYCLE TO SAFE AREA AWAY FROM GAS STATION TO ASSESS CAUSE OF LEAK. FOUND MULTIPLE CRACKS IN PLASTIC FUEL PUMP HOUSING FLANGE THAT WHICH THE HIGH PRESSURE FUEL LINE QUICK DISCONNECT THREADS INTO. FUEL WAS POOLING APPROXIMATELY ONE INCH DEEP ON TOP OF THE FUEL PUMP HOUSING AND NEXT TO FUEL PUMP ELECTRICAL CONTROL RELAY AND WIRING. MOTORCYCLE HAD TO BE TOWED 75 MILES TO NEAREST BMW MOTORCYCLE DEALER FOR FUEL PUMP AND HOUSING REPLACEMENT. *TR

NHTSA ID

10534389

Incident

Jul 17, 2013

Mileage

39,127 mi

FUEL GAUGE SHOWED 1/3 OF TANK OF FUEL REMAINING AND 110 MILES LEFT BEFORE RUNNING OUT OF GAS. BIKE RAN OUT OF GAS WHILE RIDING DOWN HIGHWAY AS TANK WAS EMPTY. WAS ABLE TO PULL OVER TO SIDE OF ROAD SAFELY AND CALL FOR ASSISTANCE. FUEL GAUGE HAS NOT READ ACCURATELY SINCE. *TR

NHTSA ID

10505404

Incident

Aug 5, 2010

Mileage

22,500 mi

PLASTIC FUEL CONNECTOR BROKE WHILE RIDING ON EXPRESSWAY - FUEL SPEWED WHILE RIDING AT 55 MPH ALL OVER RIDER'S LEG - SOAKED PANTS LEG AND BOOT. ABLE TO MAKE IT SAFELY TO MY HOME WITHOUT RUNNING OUT OF FUEL OR CATCHING FIRE. *TR

NHTSA ID

10504324

Incident

Feb 9, 2013

Mileage

9,070 mi

I STARTED THE MOTORCYCLE ENGINE. A FEW SECONDS AFTER IT STARTED, GASOLINE STARTED TO GUSH FROM THE FRONT OF THE BIKE ONTO THE ENGINE. BEFORE I KNEW IT, I WAS IN A PUDDLE OF GASOLINE. I SHUT IT OFF AS SOON AS I REALIZED WHAT WAS HAPPENING. I MOPPED UP THE GASOLINE OFF OF THE FLOOR TO ELIMINATE THE FIRE DANGER. I LOCKED THE STEERING AND PUT THE KEY AWAY AFTER THAT. *TR

NHTSA ID

10487624

Incident

Dec 6, 2012

Mileage

27,658 mi

THE FUEL PUMP CRACKED AROUND THE POINT WHERE THE FUEL LINE CONNECTS TO THE FLANGE THAT MOUNTS THE FUEL PUMP TO THE TANK. THESE CRACKS ALLOWED FUEL TO LEAK DOWN THE SIDE OF THE MOTORCYCLE AND ONTO MY CLOTHING AND THE FAIRING OF THE MOTORCYCLE. IT WAS NOT NOTICED UNTIL THE MOTORCYCLE WAS STOPPED. *TR

NHTSA ID

10485882

Incident

Apr 15, 2012

Mileage

67,000 mi

MOTORCYCLE DEVELOPED SEVERE FUEL LEAK AT THE FLANGE ON THE FUEL TANK WHERE THE FUEL LINE CONNECTS. SEVERAL CRACKS IN THE FLANGE ALLOWED FUEL TO LEAK OUT AND LAND ON ENGINE AND EXHAUST. MAJOR FIRE HAZARD!!! *TR

NHTSA ID

10485337

Incident

Nov 18, 2012

Mileage

12,219 mi

THE HIGH PRESSURE OUTLET PORT ON THE FUEL PUMP ASSEMBLY DEVELOPED CRACKS THAT EXTENDED FROM THE OUTSIDE OF THE FEMALE PORTION OF THE OUTLET INTO THE THREADS. THIS ALLOWED GASOLINE TO SPRAY ONTO THE INNER PORTION OF THE BODY MOLDING AND RAN DOWN ONTO THE ENGINE AND THE RIDERS LEG ON THE LEFT SIDE. *TR

NHTSA ID

10471642

Incident

Aug 6, 2012

Mileage

20,120 mi

ENGINE BEGAN STALLING FREQUENTLY AT END OF RIDING SEASON (FALL 2011) WHEN THE ENGINE WAS AT ITS NORMAL OPERATING TEMPERATURE. ENGINE STALLING OCCURRED WHEN DECELERATING WITH CLUTCH ENGAGED OR AT IDLE, ENGINE WOULD NOT RETURN TO NORMAL IDLE SPEED WITHOUT STALLING. THE ENGINE WAS SERVICED/MAINTAINED BY AN AUTHORIZED LOCAL BMW MOTORCYCLE DEALER ON 3/10/2012 ? 3/13/2012 WITH HOPES THAT ENGINE WOULD RETURN TO NORMAL OPERATING BEHAVIOR FOR THE FOLLOWING RIDING SEASON (2012). THIS SERVICE/ MAINTENANCE INCLUDED BUT WAS NOT LIMITED TO BMW INSPECTION WITH ANNUAL SERVICE, INCLUDES ALL FLUIDS AND VALVE ADJUSTMENT AND THROTTLE BODY SYNCHRONIZATION. BUT ON 5/6/2012 THE BIKE WAS RIDDEN ON ITS FIRST LONG RIDE OF THE SEASON. AFTER RIDING APPROXIMATELY 65 MILES THE BIKE BEGAN TO HAVE THE SAME SYMPTOMS AS DURING THE LAST RIDE IN THE FALL OF 2011. ON 5/8/2012 THE BIKE WAS TAKEN TO THE SAME LOCAL BMW MOTORCYCLE DEALER THAT PERFORMED THE ANNUAL MAINTENANCE IN MARCH. DURING THE WEEK OF 5/15/2012 THE BIKE WAS DIAGNOSED, REPAIRED AND AVAILABLE TO BE PICKED UP ON 5/18/2012. THE DIAGNOSIS FROM THE DEALER'S SERVICE TECHNICIAN IS STATED ON THE SERVICE INVOICE AS FOLLOWS: PLASTIC FUEL CONNECTOR HAD HAIRLINE CRACK CAUSING FUEL CUT RELAY TO NOT ACTIVATE WHEN DECELERATING CAUSING ENGINE TO STALL. UPGRADED PLASTIC FUEL CONNECTOR WITH METAL CONNECTOR. PARTS REPLACED WERE BMW PART NUMBERS: 16 12 1 176 918:HOSE CLAMP 13 53 7 700 800:PLUG (METAL FUEL LINE MALE CONNECTOR) N/A:FUEL HOSE CUT 1FT. *TR

NHTSA ID

10459714

Incident

May 6, 2012

Mileage

42,772 mi

THE PLASTIC FLANGE ON THE TOP OF THE FUEL PUMP /HOSE COUPLER AREA WAS FOUND TO HAVE ONE RADIAL CRACK WHICH POSSIBLY COULD HAVE RESULTED IN LEAKING FUEL UNDER PRESSURE FROM THE FUEL PUMP. THE POSSIBILITY EXISTS FOR LEAKING FUEL TO DRIP ONTO THE TOP OF THE HOT ENGINE AND RESULT IN A FIRE. *TR

NHTSA ID

10457823

Incident

May 7, 2012

Mileage

21,710 mi

THERE IS A VERY STRONG FUEL ODOR WHEN THE MOTORCYCLE IS PARKED AND WHEN IN MOTION. THE FUEL PUMP FLANGE HOUSING HAS CRACKED AND HAS ALLOWED RAW FUEL TO ESCAPE FROM THE HIGH-PRESSURE DISCONNECT. THIS IS OF GREAT CONCERN AFTER THE MOTORCYCLE HAS BEEN RIDDEN AND PARKED IN AN ENCLOSED GARAGE WHERE THE FUMES MAY COLLECT AND PRESENT A FIRE HAZARD. THIS LEAK IS WITHIN INCHES OF ELECTRICAL CONNECTIONS AND ABOVE THE LEFT EXHAUST HEADER. THIS MOTORCYCLE HAS LESS THAN 5,500 MILES WHEN THE CRACK(S) DEVELOPED. *JS

NHTSA ID

10452476

Incident

Mar 17, 2012

FUEL PUMP UNIT FLANGE CRACKED WHERE PRESSURE FITTING SCREWS IN. POTENTIAL GROSS FUEL LEAK AS REPORTED BY MANY OTHER OWNERS. *TR

NHTSA ID

10451907

Incident

Mar 16, 2012

Mileage

12,025 mi

FUEL PUMP HOUSING SPLIT AT THE DISCHARGE PORT CONNECTION. FOUR CRACKS OF EQUAL LENGTH AT 12, 3, 6 AND 9 O'CLOCK POSITIONS AROUND THE PORT. FUEL WAS PUMPED OUT OF THE CRACKS AND FLOWED ON TO THE TANK HOUSING AND THE LEFT CYLINDER. REQUIRED COMPLETE REPLACEMENT OF THE FUEL PUMP. *TR

NHTSA ID

10448325

Incident

Oct 15, 2010

Mileage

6,200 mi

OUTPUT PRESSURE BUNG (PLASTIC) IN FUEL PUMP ASSEMBLY WHERE QUICK DISCONNECT FITTING IS SCREWED IN. THE BUNG DEVELOPED SMALL RADIAL CRACKS THAT BEGAN TO LEAK GASOLINE THAT WOULD DRIP ONTO THE LEFT ENGINE CYLINDER OR ONTO DRIVER'S LEFT LEG WHILE MOVING. *TR

NHTSA ID

10448216

Incident

Oct 12, 2011

Mileage

56,856 mi

SEVERE DEEP CRACKS ALL AROUND THE PLASTIC COLLAR OF THE OUTPUT PORT OF THE SIEMENS HIGH-PRESSURE FUEL PUMP. FUEL LEAK IMMINENT, WHICH WOULD SPRAY FUEL ALL OVER THE ENGINE. IT'S COMPLETELY HIDDEN BY THE BODYWORK/FARING SO IT WAS LUCKY THAT I NOTICED IT WHILE SERVICING. EXTREMELY DANGEROUS. *TR

NHTSA ID

10448104

Incident

Feb 13, 2012

Mileage

13,000 mi

THE FUEL PUMP (SIEMENS) COLLAR ON THE FUEL LINE HAS MULTIPLE CRACKS AROUND THE QUICK CONNECT/QUICK DISCONNECT AT THE FUEL PUMP ASSEMBLY WHERE THE FUEL LINE LEAVES THE GAS TANK, THIS COULD RESULT IN A CATASTROPHIC FUEL LEAK AND FIRE. IT IS ONLY A MATTER OF TIME UNTIL THIS PLASTIC COLLAR, WHICH PROVIDES THE ANCHOR FOR THE CONNECTION FOR THE OUTGOING FUEL LINE, FAILS. I AM AWARE OF OTHER CASES OF THIS OCCURRING. *TR

NHTSA ID

10445258

Incident

Jan 25, 2012

Mileage

55,000 mi

CRACK FUEL PUMP FLANGE- LEAKING GAS; FUEL PUMP ASSEMBLY REPLACED UNDER EXTENDED WARRANTY PLAN BY LOCAL DEALERSHIP. *TR

NHTSA ID

10442023

Incident

Oct 25, 2010

Mileage

29,796 mi

HIGH PRESSURE FUEL LEAK WHERE THREADED PLASTIC QUICK DISCONNECT MATES WITH PLASTIC FLANGE ON TOP OF THE FUEL PUMP. PLASTIC FLANGE IS MOLDED INTO THE TOP OF FUEL PUMP AND HAS MULTIPLE HAIRLINE CRACKS. SPRAYED GAS WHILE BIKE WAS IDLING. NO INJURY, BUT DANGEROUS ENOUGH SITUATION TO REPORT. USE OF USED PUMPS IS NOT RECOMMENDED. I FOUND THAT USED PUMPS HAD SIMILAR CRACKING; ONLY OPTION WAS TO HAVE BMW DEALERSHIP REPLACE WITH NEW PUMP. *TR

NHTSA ID

10435968

Incident

Mar 12, 2011

Mileage

73,000 mi

THREE CRACKS IN THE PLASTIC FLANGE AROUND THE HIGH PRESSURE QUICK DISCONNECT ON TOP OF THE FUEL PUMP. THE ENGINE WAS STARTED AND WITHIN A VERY SHORT TIME I FOUND MYSELF AND THE MOTORCYCLE STANDING IN A 6 FOOT DIAMETER CIRCLE OF GASOLINE ON THE CONCRETE FLOOR A SERIOUS CONDITION THAT COULD HAVE IGNITED FROM THE RUNNING ENGINE WITH POTENTIALLY DEADLY RESULTS. INVESTIGATION REVEALS THAT THIS APPEARS TO BE MOUNTING PROBLEM WITH NUMEROUS R1200 RT BMW MOTORCYCLES EXPERIENCING THE SAME PROBLEM WHICH MAY EVENTUALLY END UP WITH SOMEONE GETTING SERIOUSLY HURT. IT IS MY UNDERSTANDING THAT THIS ISSUE HAS BEEN REPORTED TO NHTSA MY OTHERS. THE INITIAL REPORT I BELIEVE TO BE JBN1-18051 I DO HAVE DIGITAL PICTURES OF THE FAILURE AVAILABLE IF REQUIRED. *TR

NHTSA ID

10435325

Incident

Nov 4, 2011

Mileage

32,000 mi