2005 BMW R Series

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

UNLIKE MOST MOTORCYCLES, WHERE A SIGHT GLASS IS USED TO DETERMINE ENGINE OIL LEVEL, THE SUBJECT, AIR-COOLED, MOTORCYCLES ARE BUILT BY BMW WITH A POLYMER (PLASTIC) SIGHT GLASS THAT, IN SOME INSTANCES, MELTS DUE TO HIGH ENGINE/OIL TEMPERATURE.THIS TYPICALLY OCCURS WHEN THE MOTORCYCLE IS OPERATED CONTRARY TO BMW'S OWNER MANUAL ADMONITION: WARNING:DO NOT KEEP THE ENGINE RUNNING WHILE THE MOTORCYCLE IS AT A STANDSTILL -- RISK OF OVERHEATING AND FIRE.EACH OF THE ALLEGED FIRES OCCURRED WHILE THE MOTORCYCLE WAS PARKED AND IDLING.ODI IS UNAWARE OF ANY STRUCTURE FIRES WHERE A MELTED SIGHT GLASS IS THE ROOT CAUSE.OF THE EIGHT KNOWN FIRES, ONE OCCURRED IN 2000, THREE IN 2004 AND AGAIN IN 2005, AND ONE IN FEBRUARY, 2007.THE SUBJECT VEHICLES DO NOT HAVE AN ELEVATED FIRE-RELATED INSURANCE CLAIMS HISTORY. BASED ON THE LOW INCIDENCE RATE, IT APPEARS BMW'S WARNING IS EFFECTIVE AND NO DEFECT TREND IS IDENTIFIED.FURTHER USE OF AGENCY RESOURCES APPEARS UNWARRANTED.THIS INVESTIGATION'S CLOSING DOES NOT CONSTITUTE A NHTSA FINDING THAT NO SAFETY-RELATED DEFECT EXISTS AND WE RESERVE THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED.

CRACK IN THE FUEL PUMP CONTROLLER HOUSING RESULTING IN MINOR FUEL LEAK. *TR

NHTSA ID

10485434

Incident

Nov 1, 2012

Mileage

31,000 mi

TL*THE CONTACT OWNS A 2005 BMW R-1200. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS AND TRYING TO DOWNSHIFT THE REAR OF THE VEHICLE WOULD LIFT UPWARD. THE FAILURE CAUSED THE FRONT BRAKES TO UNLOCK AND THE FRONT WHEEL MAKING IT DIFFICULT TO STOP. THE VEHICLE WAS INSPECTED BY A DEALER WHO INFORMED THE CONTACT THAT HE NEEDED TO REPLACE THE ANTI-HOP CLUTCH FOR THE FRONT BRAKES. THE VEHICLE WAS REPAIRED FOR THE FATCAT ANTI-HOP CLUTCH. THE FAILURE MILEAGE WAS APPROXIMATELY 20,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10371815

Incident

Jul 1, 2010

Mileage

20,000 mi

WHILE WAITING AT A RED LIGHT IN TRAFFIC ON A HIGHWAY, I PULLED IN THE CLUTCH, PUT THE BIKE INTO GEAR AND THE BIKE MADE A LOUD, METALLIC GRINDING SOUND. THIS FAILURE ONLY HAPPENED ONCE IN THE TIME I HAVE OWNED THIS MOTORCYCLE (2 1/2 MONTHS); HOWEVER, IT WAS A CATASTROPHIC FAILURE OF THE DRIVETRAIN THAT LEFT MY BIKE UNABLE TO TRAVEL UNDER ITS OWN POWER AND STRANDED ME IN THE MIDDLE OF HEAVY, FAST MOVING TRAFFIC. (THIS HAPPENED ON THE WEST SIDE HIGHWAY IN MANHATTAN.) FOR MY PERSONAL SAFETY AND TO PREVENT MY DISABLED MOTORCYCLE FROM CAUSING AN ACCIDENT, I HAD TO PUSH THE BIKE TO THE SIDE OF THE ROAD THROUGH GAPS IN TRAFFIC. THE REPAIR REQUIRED A FULL CLUTCH REPLACEMENT AND REPLACEMENT OF THE INPUT SHAFT TO THE TRANSMISSION (WITHRELATED SEALS AND SHIMS.) *TR

NHTSA ID

10353703

Incident

Jul 11, 2010

Mileage

20,300 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.

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.

Discharged Battery Energy Diagnosis Must Be Performed: 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. In order to properly repair the vehicle the first time in the workshop, it is very important that the diagnostic test plans are performed to completion, with all results taken into consideration. Without performing the energy diagnosis test plan, the root cause of the discharged battery cannot be identified. This increases the chances of a repeat repair.

Bluetooth issues between Navigators, mobile phones, communication and audio systems.

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.

BMW MC: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. INFORMATION PROVIDED REGARDING THE WARRANTY EXTENSION, WITH OUT MILEAGE LIMITATIONS, TO 12 YEARS DUE TO A POTENTIAL DURABILITY ISSUE WITH FILM TYPE FUEL LEVEL SENDER FUEL STRIP. MODEL 2005-2013 R, K SERIES. *PE