2009 BMW R 1200 RT Fuel system Problems

The OEM plastic 90° quick discount fitting on top of the fuel pump started spraying fuel. I started smelling fuel on the interstate highway 10 and by the time I could pull over safely off the interstate I was covered with fuel. The fuel was running down on the hot exhaust pipe’s on the front left side of the motorcycle and spraying all over my face and legs. I could have been set on fire and burnt to death because of where the fuel was spraying from. This also could have cost the lives of the people on the interstate had i burst into flames and lost control of the motorcycle. When I called the BMW dealership in Tucson AZ the service tech told me that they had a medal aftermarket 90° fitting that would fix my problem. I replaced the fitting and the fuel leak was fixed. This motorcycle fuel pump was replaced 07/01/2014 at mileage 12,482 because of a fuel leak recall. I’m filling this report because this fitting fail happened without warning 15,700 miles after the fuel flange recall. This must be a common problem for the service tech to know over the phone the fox and have a aftermarket medal part that fixed the fuel leak. The location of this potential leak makes it extremely dangerous hazard.

NHTSA ID

11495808

Incident

Nov 22, 2022

Throttle body cams broken, no symtoms, could have caused crash from complete power loss to the engine, could have crashed or been hit. Dealer replaced.

NHTSA ID

11430264

Incident

Jul 7, 2021

MY SECOND MOTORCYCLE TO HAVE THROTTLE BODY CAM FAILURE. THIS IS BECOMING AN ISSUES AS THESE BIKE REACH HIGHER MILEAGE.

NHTSA ID

11416743

Incident

May 15, 2021

Mileage

75,600 mi

BMW HAVE RECALL CAMPAIGN NO. 20V-471: FUEL PUMP. THE DEALER IN MY AREA (5TH GEAR CYCLE 1200 W SW EXPY DR, BROKEN ARROW, OK 74012) IS NOT ABLE TO SCHEDULE SERVICE BEFORE END OF JULY. BIKE CURRENTLY IS UNUSABLE AS FUEL DRIPS OVER THE EXHAUST.

NHTSA ID

11414608

Incident

Feb 23, 2021

THROTTLE BODY PLASTIC CAMS BROKE ACCELERATING INTO ON RAMP OF I4 IN ORLANDO. THIS CAUSED THE VEHICLE TO IMMEDIATELY SLOW DOWN TO IDLE INTO REAR APPROACHING TRAFFIC.

NHTSA ID

11414511

Incident

Apr 12, 2021

Mileage

96,867 mi

2009 BMW R1200RT MOTORCYCLE WITH 50,482 MILES. THROTTLE CABLE PULLEYS/CAMS BOTH SHOWING SIGNS OF MULTIPLE CRACKS. ONCE THEY CRACK COMPLETELY, THE MOTORCYCLE BECOMES UNRIDEABLE AND MUST BE TOWED. THROTTLE NO LONGER FUNCTIONS AND MOTORCYCLE JUST RETURNS TO IDLE. MUST EITHER REPLACE ENTIRE THROTTLE BODY OR REMOVE AND REPLACE EXISTING PLASTIC CAMS WHICH HAVE FAILED.

NHTSA ID

11414323

Incident

Apr 28, 2021

Mileage

55,000 mi

AFTER ENTERING THE INTERSTATE FUEL BEGAN SPEWING FROM THE UPPER LEFT FAIRING AREA. I PULLED OFF AND SHUT IT DOWN. I COULDN'T TELL WHERE IT ORIGINATED FROM. IT DIDN'T APPEAR ANY LONGER SO I DECIDED TO RETURN HOME, ABOUT 2 MILES. UPON ENTERING THE INTERSTATE AGAIN FUEL SPEWED OUT WITH SUCH FORCE IT COVERED MY ENTIRE LEFT SIDE AND LEG. I PULLED OFF ASAP. A MOTORIST SAW ME AND STOPPED TO HELP. HE WAS AFRAID OF A FIRE, AS I WAS, AND PULLED OUT AN EXTINGUISHER. FUEL WAS EVERYWHERE. HE HELPED ME TOW IT HOME.

NHTSA ID

11172736

Incident

Jan 28, 2019

Mileage

2 mi

2014 RECALL ON THE FUEL PUMP FLANGE WAS ISSUED AND IT WAS COMPLETED AT A BMW DEALER IN JUNE OF 2014. NOW MAY 6, 2018 THE FUEL PUMP FLANGE HAS FAILED SPRAYING FUEL OVER THE ENGINE. I CONTACTED THE BMW CUSTOMER SERVICE DEPARTMENT THEY INFORMED ME THAT DUE TO THE PART BEING OVER 2 YEARS OLD AND THEY NO LONGER RESPONSABLE FOR THE REPLACEMENT OF THE PART. THIS IS THE SAME ISSUE FOR THE 2014 RECALL AND NOW IT HAS HAPPENED AGAIN.

NHTSA ID

11092504

Incident

May 7, 2018

Mileage

37,000 mi

THE VEHICLE HAS 52500 MILES. AFTER FUELING THE MOTORCYCLE I ATTEMPTED TO RESET THE TRIP ODOMETER IN THE NORMAL WAY BY TURNING THE THROTTLE TO MAXIMUM WHILE HOLDING THE BC BUTTON ON THE DASHBOARD. BIKE WAS ON, ENGINE NOT RUNNING. THE PLASTIC PULLEYS ON BOTH THROTTLE BODIES SNAPPED SUDDENLY, LEAVING THE THROTTLE BODY SET TO FULL THROTTLE. I VERIFIED THIS BY STARTING THE BIKE. IF THIS PULLEY FAILURE HAD HAPPENED WHILE IN MOTION IT COULD HAVE RESULTED IN AN ACCIDENT. THE THROTTLE BODY PULLEYS ARE NOT REPLACEABLE NOR ARE THE THROTTLE BODIES SERVICEABLE. AFTER A PERIOD OF TIME THE PLASTIC PULLEY DETERIORATES DUE TO HEAT AND LOSES STRENGTH. I REGARD THIS AS A DEFECTIVE DESIGN AND SAFETY HAZARD. THE PART SHOULD BE METAL AS ON PREVIOUS MODELS. MY R1100RT HAS 150,000 MILES AND NO ISSUES WITH THE TB PULLEYS. I WOULD URGE THAT BMW BE REQUIRED TO RECALL THE 2005-2009 MODELS WITH THESE PLASTIC PULLEYS AND REPLACE WITH METAL ONES OR THAT THEY WARRANTY THE REPAIR WHEN THIS FAILURE OCCURS.

NHTSA ID

11023849

Incident

Sep 2, 2017

Mileage

52,500 mi

RE: VIN [XXX] DEAR BMW MOTORCYCLES OF AMERICA I DEVELOPED A SERIOUS AND SIGNIFICANT FUEL LEAK TODAY FROM THE LEFT SIDE OF MY FAIRING/ TANK OF MY R1200RT. THE FUEL ONLY LEAKED WHEN THE KEY WAS ON, OR THE ENGINE WAS RUNNING, INDICATING THE FUEL WAS COMING FROM THE PRESSURIZED SIDE OF THE FUEL CIRCUIT, FROM LIKELY THE FUEL PUMP FLANGE. THERE IS EVIDENCE IN FORUMS AND THE RESPONSES FROM OWNERS TO DEALERS THAT THIS FUEL PUMP FLANGE CRACKING IS A COMMON ISSUE, AND THAT THERE HAS BEEN A RECALL ISSUED (13V617000) FOR REPAIR AND REPLACEMENT. I AM THE ORIGINAL OWNER OF THIS BIKE AND I NEVER RECEIVED A NOTICE FROM BMW REGARDING THIS ISSUE, AND WHEN I TRY TO ENTER MY VIN WITH THE BMWUSA.COM SITE AS WELL AS WITH NHTSA.GOV (SAFERCAR.GOV), I CANNOT MAKE PROGRESS BECAUSE I AM TOLD MY VIN IS INVALID. THIS IS NOT SO, AS I HAVE HAD OTHER WARRANTY WORK NOTIFIED AND COMPLETED VIA THIS VIN. (REPEATED FUEL STRIP SENSOR FAILURE, AND THE REAR WHEEL FLANGE CRACK RECALL). PLEASE CONTACT ME REGARDING THIS FUEL LEAK RECALL ISSUE AND HELP ARRANGE APPROPRIATE REPAIRS AND REPLACEMENT. THIS IS A FAILURE OF A PART THAT IS NOT NORMAL WEAR AND TEAR, AND POSES A SIGNIFICANT SAFETY RISK FOR FIRE. SINCERELY, INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

11005469

Incident

Jul 15, 2017

Mileage

24,400 mi

TL* THE CONTACT OWNS A 2009 BMW R 1200 RT. THE CONTACT STATED THAT WHILE PARKED IN THE GARAGE, A ODOR OF FUEL WAS PRESENT. THE MOTORCYCLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL TANK HAD CRACKED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND THE CONTACT WAS INFORMED THAT THE FUEL TANK WAS PREVIOUSLY REPLACED UNDER NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM) IN 2014. THE MOTORCYCLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 30,000.

NHTSA ID

10924600

Incident

Aug 24, 2016

Mileage

30,000 mi

WHEN SHIFTING INTO SECOND GEAR, THE ENGINE SPEED DROPPED TO IDLE AND I LOST ALL POWER AND THE ABILITY TO CONTROL ENGINE SPEED. I COASTED TO THE SHOULDER AND HAD TO CALL FOR A TOW AS THE BIKE WOULD ONLY IDLE. UPON FURTHER INSPECTION AFTER I GOT THE BIKE HOME, I DISCOVERED THAT THE PLASTIC PULLEYS ON THE THROTTLE BODIES HAD SHEARED OFF. THIS REQUIRES REPLACEMENT OF THE THROTTLE BODIES. I WAS SHOCKED TO FIND OUT THE PULLEYS ARE PLASTIC. PREVIOUS MODELS WERE METAL AND MOST CARS/BIKES USE METAL, WHICH WOULD BE MORE RESISTANT TO FAILURE. TO QUOTE ANOTHER COMPLAINT: "IF OR WHEN THE PLASTIC FAILS, THERE IS NO THROTTLE AND THE ENGINE GOES TO IDLE, THUS CREATING AN EXTREME SAFETY HAZARD IF ONE IS DRIVING IN TRAFFIC AND UNABLE TO MAINTAIN SPEED OR ACCELERATE. IN THIS CIRCUMSTANCE THE RIDER COULD BE FORTHRIGHTLY IN HARM'S WAY AND ENDANGERED. THIS SHOULD BE AN URGENT RECALL ISSUE FOR REPLACEMENT OF THE PLASTIC PART WITH A SOLID CABLE PULLEY WHICH WILL NOT BREAK. PREVIOUS MODELS USED METAL CABLE PULLEYS WHICH DID NOT FAIL." THIS IS A POTENTIAL DANGER. IF SOMEONE HAD BEEN ACCELERATING BEHIND ME, I COULD HAVE BEEN REAR ENDED. BMWS INTRANSIGENCE IS MIND BOGGLING. *TR

NHTSA ID

10671553

Incident

Jan 7, 2015

Mileage

29,843 mi

BMW MODEL R1200RT YEARS 2005 - 2013 MAY BE SUBJECT TO THROTTLE CABLE ASSEMBLY FAILURE. THE THROTTLE BODY SYSTEM ON THE 2009 YEAR MODEL IS ASSEMBLED BY BING POWER IN NUREMBERG, GERMANY AND UTILIZED BY BMW IN MOTORCYCLES WITH THE 1170 CC BOXER MOTOR. (BING IS A LONGSTANDING COMPANY WHICH IN GENERAL MANUFACTURES FIRST-RATE PRODUCTS.)THE PRIMARY THROTTLE CABLE EXTENDS FROM THE HANDLE BAR TO A SPLITTER FROM WHICH TWO SEPARATE THROTTLE CABLES EXTEND TO LEFT AND RIGHT HAND THROTTLE BODIES WHICH HOUSE THE FUEL INJECTION SYSTEM. THOSE TWO CABLES ARE ROUTED OVER AND ANCHORED TO A CABLE PULLEY MADE OF MOLDED PLASTIC. THIS ENTIRE ASSEMBLY IS ATTACHED TO THE THROTTLE BODY. IF OR WHEN THE PLASTIC FAILS, THERE IS NO THROTTLE AND THE ENGINE GOES TO IDLE, THUS CREATING AN EXTREME SAFETY HAZARD IF ONE IS DRIVING IN TRAFFIC AND UNABLE TO MAINTAIN SPEED OR ACCELERATE. IN THIS CIRCUMSTANCE THE RIDER COULD BE FORTHRIGHTLY IN HARM'S WAY AND ENDANGERED. THIS SHOULD BE AN URGENT RECALL ISSUE FOR REPLACEMENT OF THE PLASTIC PART WITH A SOLID CABLE PULLEY WHICH WILL NOT BREAK. PREVIOUS MODELS USED METAL CABLE PULLEYS WHICH DID NOT FAIL. (SEE THIS BLOG FOR DISCUSSION POSTED BY ANOTHER RIDER, AMONG MANY, WITH THE SAME FAILURE ISSUE: HTTP://WWW.ASVRIDER.COM/FORUMS/SHOWTHREAD.PHP?T=967780&PAGE=3 ) BMW DOES NOT MAKE THE PLASTIC PART AVAILABLE FOR REPLACEMENT. THUS, A PLASTIC PART COSTING BUT A FEW DOLLARS RESULTS IN THE RIDER HAVING TO REPLACE BOTH THE LEFT AND RIGHT COMPLETE THROTTLE BODY ASSEMBLIES AT A COST OF MORE THAN $1,000. THE UNDER-DESIGNED PLASTIC CABLE PULLEY IS NOTHING LESS THAN A HAZARD AND CREATES A RISK TO ONE'S LIFE. A POLICE MOTORCYCLE COP RIDING HIS PATROL R1200RT LOOKED AT THE FAILED PART I SHOWED HIM AND HIS FIRST WORDS WERE, "THAT COULD GET YOU KILLED." I HAVE MADE BING AND BMW OF NORTH AMERICA AWARE OF MY EXPERIENCE VIA EMAIL BUT I CONTINUE TO WAIT FOR THEIR REPLY. *TR

NHTSA ID

10609639

Incident

Jul 2, 2014

Mileage

48,832 mi

FUEL STRIP FAILED, GOING FROM APPROXIMATELY 150 MILES TO EMPTY TO --- MILES TO EMPTY IMMEDIATELY. FUEL STRIP WAS REPLACED 5 TIMES IN TOTAL BEFORE I SOLD THE MOTORCYCLE 6/15/13 WITH ~7,500 MILES ON THE BIKE. *TR

NHTSA ID

10543839

Incident

May 14, 2011

Mileage

1,700 mi

AFTER STARTING THE MOTORCYLE AND ALLOWING FOR A BRIEF PERIOD OF WARMING UP, I HEADED TO THE GAS STATION TO FUEL UP IN PREPARATION FOR A LONG RIDE THE NEXT DAY. AS A FORCE OF HABIT I CHECKED MY RANGE AND ODOMETER READINGS AND FOUND THE RANGE WAS NOTICEABLY LOWER THAN IT SHOULD BE DISPLAYING FOR THE MILES USED ON THE TANK. AS I RODE THE COUPLE OF MILES TO THE GAS STATION THE RANGE CONTINUED TO DROP PRECIPITOUSLY, 5-20 MILES AT A TIME EVERY FEW SECONDS UNTIL IT REACHED ZERO AND DISPLAYED "---" FOR A RANGE TO EMPTY AFTER RIDING JUST OVER ONE MILE. AFTER FILLING THE TANK FULLY, THE GAUGE DID NOT RESET OR CHANGE IN ANY WAY. I TOOK THE MOTORCYCLE TO THE DEALER AND THEY DIAGNOSED THE PROBLEM AS A FUEL STRIP, AKA FUEL LEVEL SENSOR, GONE BAD. I AM NOW AWAITING THE PART TO ARRIVE SO MY 3RD FUEL STRIP REPLACEMENT CAN GO AHEAD. (MY SECOND OCCURRED IN FEBRUARY 2012, THE THIRD IN AUGUST 2013.) MY MOTORCYCLE HAS JUST 24,000 MILES AND IS LESS THAN 5 YEARS OLD (BY 3 MONTHS). I FIND IT ALMOST UNFATHOMABLE THAT SUCH AN ESSENTIAL PART AS THE FUEL GAUGE CAN CEASE TO FUNCTION FOR NO APPARENT REASON, WITH NO WARNING ON A MODERN VEHICLE. ADD IN THE DENIALS FROM THE MANUFACTURER THAT A PROBLEM EVEN EXISTS AND IT GETS TOTALLY MADDENING.

NHTSA ID

10538096

Incident

Jun 16, 2010

Mileage

4,500 mi

MOTORCYCLE RAN OUT OF FUEL DUE TO FUEL SENSOR FAILURE. BOTH ANALOG AND DIGITAL GAUGES SHOWED 40+ MILES REMAINING IN THE FUEL TANK. VEHICLE WAS IN FAST LANE OF INTERSTATE HIGHWAY AND MY EMERGENCY STOP REQUIRED STATE PATROL ASSISTANCE DO TO THE LOCATION OF THE STOP. *TR

NHTSA ID

10514560

Incident

May 14, 2013

Mileage

31,200 mi

RIDING ON THE INTERSTATE WITH TRAFFIC, THE FUEL GAUGE BEGAN ACTING ERRATICALLY, SHOWING MORE FUEL, THEN LESS FUEL FOR A FEW MILES BEFORE THE MOTORCYCLE RAN OUT OF FUEL, ALMOST CAUSING A CRASH AS THE ENGINE QUIT. WAS ABLE TO CHANGE LANES AND GET TO THE SHOULDER WITHOUT A CRASH. I FEEL THIS IS A SIGNIFICANT SAFETY ISSUE. IF THE FUEL GAUGE (WHICH IS FED DATA FROM A FAULTY FUEL STRIP) READS MORE FUEL THAN THE VEHICLE ACTUALLY HAS, IF THE ENGINE RUNS OUT OF FUEL AND STOPS, THIS COULD BE VERY DANGEROUS IN PLACES WITH HIGH TRAFFIC COUNTS AND SPEED. *TR

NHTSA ID

10499353

Incident

Nov 20, 2012

Mileage

58,500 mi

AT THE TOP OF THE FUEL PUMP, WHERE THE FUEL LINE QUICK DISCONNECT IS THREADED INTO THE HOUSING, MULTIPLE CRACKS HAVE DEVELOPED IN THE FUEL PUMP HOUSING. *TR

NHTSA ID

10492199

Incident

Jan 10, 2013

Mileage

26,422 mi

THE FUEL LEVEL SENSOR HAS FAILED (TWICE) AND HAS BEEN REPLACED BY THE BMW MOTORCYCLE DEALERSHIP. THE LATEST FUEL LEVEL SENSOR IS NOT WORKING PROPERLY EITHER AND WILL EVENTUALLY BE REPLACED AGAIN BEFORE THE WARRANTY EXPIRES IN FEB 2013. *TR

NHTSA ID

10485368

Incident

Oct 23, 2012

Mileage

7,013 mi

THE DIGITAL STRIP FUEL GAUGE SIMPLY FROZE IN THE FULL POSITION, IT NO LONGER REGISTERS NOR DOES THE MILES REMAINING DIGITAL READOUT. *TR

NHTSA ID

10485317

Incident

Sep 1, 2012

Mileage

13,000 mi