2008 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

The bike is a 2008 BMW R1200RT. The throttle bodies for each cylinder has a plastic cam that is the point of attachment for the throttle cable. That plastic cam broke and completely detached from the bike. I was accelerating to merge into traffic on Interstate 64E at Corydon, IN. Once established in the right lane, the bike suddenly lost power and slowed rapidly while I was approached from the rear by a tractor trailer that had to apply brakes and continuously sounded his horn while abruptly maneuvering to the left lane to avoid me while I was attempting to assess what had just happened. This is a critical safety component and its failure has been documented countless number of times on various owner's group forums for this type of bike. One of which is linked here: https://www.bmwsporttouring.com/topic/91897-throttle-body-more-cracked-cable-camspulleys/ Another: https://forums.bmwmoa.org/showthread.php?76036-Broken-Throttle-Body-Pulleys-2009-R1200RT/page5 It is apparent the plastic that this throttle body cam is made from deteriorates rapidly causing a significant safety risk. There are aftermarket replacements that are made from aluminum, but they are very expensive. I am asking for a safety recall and that BMW be made to replace these parts with a metal or a material that is less prone to failure.

NHTSA ID

11460528

Incident

Apr 10, 2022

My forth vehicle with throttle body cams that are cracked and broken on both sides. No symptoms or warning lights of a problem that could have lead to a catastrophic failure, total engine propulsion failure, breakdown. My safety and others were in danger of injury or death. Dealer has confirmed and repaired all vehicles.

NHTSA ID

11430262

Incident

Aug 2, 2021

This is a two-cylinder engine with an independent throttle body for each cylinder. The throttle is actuated by a cable and pulley which rotate the throttle plate on a shaft. The pulley is attached to the shaft with molded plastic. Upon inspection during service, both plastic moldings (both cylinders) were discovered to be cracked and near failure. Failure of this part will cause that cylinder to go to idle power. If the vehicle is in motion, there will be a sudden loss of power, and high vibration until the throttle is closed. Until repair, the motorcycle will be inoperable. This has become a known defect with this series of motorcycles. I repaired mine using an aftermarket aluminum part created to address this problem. Parts cost was $458.

NHTSA ID

11423380

Incident

Apr 23, 2019

THIS SERIES OF MOTORCYCLES HAS A COMMON PROBLEM WITH CRACKS IN THE THROTTLE PULLEYS ON THE THROTTLE BODY. FAILURE OF THIS PLASTIC PART WILL RESULT IN INSTANT LOSS OF POWER. I HAVE BEEN READING ABOUT THIS PROBLEM, AND DECIDED TO INSPECT THE TWO THROTTLE BODIES ON MY MOTORCYCLE AS A PRECAUTION. BOTH OF MINE WERE CRACKED. ONE OF THE PULLEYS HAS THREE CRACKS IN IT, AND WOULD LIKELY HAVE FAILED WITHIN A SHORT TIME. SEE PHOTOS INCLUDED WITH THIS REPORT.

NHTSA ID

11202929

Incident

Apr 22, 2019

Mileage

42,000 mi

ABS PUMP MOTOR IS FAILING ON MANY OF THE SAME MODEL BIKES AND SOME OTHER 2006-2008 MODEL BMW BIKES WITH LOW MILEAGE, BECAUSE THE BRUSH HOLDERS IN THE ABS ELECTRICAL MOTOR ARE TOO TIGHT AND BRUSHES GET STUCK IN THEM - BAD DESIGN OF THE ABS PUMP MOTOR. BMW WILL ASK YOU LOADS OF MONIES FOR THE REPLACEMENT OF THE PUMP, EVEN THO THEY ARE FULLY AWARE IT'S A PROBLEM WITH MANY OF THE BIKES.

NHTSA ID

11131018

Incident

Jul 26, 2017

Mileage

30,000 mi

FUEL PUMP LEAKING FROM A CRACK IN THE HIGH PRESSURE OUTPUT LINE SPRAYED GASOLINE ON THE INSIDE OF THE FAIRING, MOTOR AND MY LEG. THE PUMP SPRAYS GASOLINE ANYTIME THE KEY IS IN THE ON POSITION.

NHTSA ID

11013884

Incident

Aug 8, 2017

Mileage

12,000 mi

VEHICLE BEGAN EXHIBITING ENGINE STALLING SYMPTOMS FOR ABOUT A MONTH (ENGINE DIES WITHOUT WARNING AS IF IGNITION HAD BEEN CUT) DURING CITY DRIVING, WHILE TURNING AND PULLING INTO A PARKING SPACE AT ABOUT 5 MPH, THE VEHICLE ENGINE QUIT ALONG WITH INSTRUMENT PANEL GOING BLANK. ELECTRICAL SMOKE BEGAN TO BILLOW BETWEEN THE FRONT FORKS. THIS LASTED FOR ABOUT 10 SECONDS. AFTER GETTING THE VEHICLE HOME, I DISCOVERED THAT THE FIRE APPEARED TO HAVE ORIGINATED IN THE IGNITION WIRING HARNESS SOMEWHERE BETWEEN THE FRONT FORKS. THE HARNESS WRAP APPEARS TO HAVE FRICTION WEAR INDICATIONS EXPOSING BARE WIRING. THE FAULTY WIRE MELTED THE INSULATION ALL THE WAY FROM THE IGNITION SWITCH DOWN INTO THE MAIN WIRING HARNESS THAT IS ROUTED UNDER THE FUEL TANK.

NHTSA ID

10968858

Incident

Mar 17, 2017

Mileage

35,000 mi

THE BRAKE FAILURE LIGHT CAME ON, BMW SHOP SAID ABS UNIT IS BAD $2000 FIX. ON MANY BMW MOTORCYCLE FORUMS THERE ARE MANY ABS UNIT FAILURES. BMW KNOWS ABOUT THESE FAILURES BUT DOES NOTHING.

NHTSA ID

10944497

Incident

Jan 9, 2017

Mileage

22,000 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.

Multiple factors may cause the driveshaft to become damaged; among them are corrosion in certain parts ofthe driveshaft, and wear and tear exacerbated by certain climatic conditions.

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.