2005 BMW R 1200 ST

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

THROTTLE CABLE BELL CRANKS CRACK DUE TO POOR QUALITY PLASTIC MATERIAL. THIS CAUSES MOTORCYCLE TO SUDDENLY LOSE POWER AS HAND THROTTLE NO LONGER WORKS, AND ENGINE RETURNS TO IDLE SPEED. THIS CAN LEAD TO A SERIOUS SAFETY HAZARD IF THIS OCCURS ON HIGH SPEED ROADWAYS, FREEWAY ETC. MY VEHICLE WAS BEING SERVICED WHEN THE CRACKS (AND IMPENDING FAILURE) WERE NOTICED BY SERVICE PERSONNEL.

NHTSA ID

11407418

Incident

Apr 4, 2021

Mileage

18,282 mi

FUEL LEAKS FROM THE FRONT LEFT SIDE OF THE MOTORCYCLE DRIPPING ONTO THE CYLINDER HEAD AND EXHAUST PIPE. THE SOURCE OF THE LEAK IS THE QUICK DISCONNECT FITTING AT THE FUEL PUMP. *TR

NHTSA ID

10544088

Incident

Sep 10, 2013

Mileage

42,105 mi

1) SMELLED FUEL WHILE RIDING, SAW FUEL LEAKING ONTO HOT MOTOR, STOPPED IMMEDIATELY. 2) A PLASTIC QUICK-DISCONNECT COUPLER HAD CRACKED ALLOWING FUEL AT HIGH PRESSURE TO SPRAY ONTO HOT MOTORCYCLE ENGINE. AIR COOLED MOTOR, EXTREME FIRE RISK. 3) BMW PART # IS 13537674765, MADE BY COLDER PRODUCTS COMPANY. PART IS PLASTIC, BECOMES BRITTLE AND CRACKS OR BREAKS OFF ON THE MALE SIDE OF CONNECTOR. THERE ARE TWO LINES (FEED & RETURN) SECOND PLASTIC COUPLER BROKE OFF DURING DISASSEMBLY. CPC ALSO MAKES THE EXACT SAME QUICK- COUPLER IN CHROME PLATED BRASS, I REPLACED BOTH PLASTIC CONNECTORS WITH METAL ONES. TOTAL COST OF REPAIR WAS LESS THAN $100 INCLUDING NEW CLAMPS & O-RINGS. I HAVE THE OLD PARTS, BUT THIS IS A COMMON PROBLEM, KNOWN TO BMW AND MANY HAVE FAILED. ALL BMW R1200RT, R1200ST, R1200GS MODELS HAVE THESE FUEL LINE QUICK-DISCONNECTS SITTING ON TOP OF THE MOTOR CONNECTING THE FUEL TANK. THEY SHOULD BE RECALLED BEFORE SOMEONE BURNS TO DEATH ON THEIR BIKE. *TR

NHTSA ID

10403724

Incident

May 28, 2011

Mileage

8,000 mi

I OWN A 2005 BMW R1200ST MOTORCYCLE, IT HAS 28,837 MILES ON IT AND THE QUICK DISCONNECTS FOR THE FUEL TANK ARE PLASTIC AND WILL/DO BREAK UNEXPECTEDLY. THUS UPON NOTICING THIS CONDITION I PROCEEDED TO REPLACE THE PLASTIC WITH STEEL PARTS WHERE AS WHEN THE MALE TO FEMALE THREADED PLUG WAS CHANGED THE PLASTIC FUEL PUMP HOUSING CRACKED AND RENDERED THE MOTORCYCLE INOPERABLE UNTIL A REPLACEMENT FUEL PUMP CAN BE SHIPPED FROM GERMANY.THIS TRANSFERS THE FUEL UNDER PRESSURE TO THE EFI AND WHEN TURNED ON WITH THE CRACK SPRAYS/LEAKS FUEL OVER THE SIDE OF THE MOTORCYCLE ONTO THE HOT EXHAUST. THE MOTORCYCLE WAS TRAILERED TO THE DEALER WHERE THE PART WAS ORDERED FROM GERMANY WITH A TWO WEEK WAIT AT THE PRICE OF $475.00 PLUS S&H AND INSTALLATION CHARGES YET TO BE DETERMINED. *TR

NHTSA ID

10394088

Incident

Mar 26, 2011

Mileage

28,837 mi

BMW 2005 R1200ST FINAL DRIVE FAILURE. *TR

NHTSA ID

10212376

Incident

Dec 12, 2007

Mileage

35,000 mi

INTERFERENCE FIT WHEEL ADAPTER ON FINAL DRIVE AXLE TUBE LOST IT'S PROPER FIT CAUSING THE REAR WHEEL TO DEVELOP A WOBBLE GREATER THAN 1 MM (3 MM) AT 15,750 MILES AND 18 MONTHS OF USE. WHEEL CREATED A HANDLING PROBLEM. A NEW SPLINED ADAPTER WAS INTERFERENCE FIT TO THE EXISTING AXLE TUBE SPLINE ON THE FINAL DRIVE. *TR

NHTSA ID

10208967

Incident

Oct 19, 2007

Mileage

15,750 mi

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