2007 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.

PROMPTED BY AN ARTICLE RELEASED REGARDING THIS VEHICLE MODEL'S FUEL PUMP/PUMP COVER OUTLET BOSS AND FITTING ASSEMBLY FRACTURING AND LEAKING FUEL I INSPECTED MINE. ABOUT 3/4 OF THE BOSS IS VISIBLE FOR INSPECTION. IT IS CRACKED IN SEVEN PLACES. CRACKS ARE VERTICAL, STARTING AT THE BOSS BASE TERMINATING AT IT'S RIM. THIS BIKE HAS ALWAYS HAD A SLIGHT SMELL OF FUEL THOUGH I'VE NEVER LOCATED THE SOURCE. AT THIS TIME I DON'T THINK I HAVE A LEAK AT THE PUMP BOSS (YET). THE LIGHT COAT OF DUST DOES NOT SHOW DISRUPTION BY FUEL RESIDUE. I'M CONCERNED ABOUT MY FUTURE SAFETY. I EXPECT THE COMPONENT TO FURTHER DETERIORATE. I'M CONCERNED ABOUT THE COST OF REPAIR AS THERE ARE NO INDIVIDUAL COMPONENTS FOR CORRECTING THIS ISSUE. PUMP AND CAP IS OVER $500. MUCH TO PAY FOR A SMALL BIT OF PLASTIC TO FAIL. *TR

NHTSA ID

10485355

Incident

Nov 20, 2012

Mileage

32,914 mi

MOTORCYCLE SHIFTED FROM 1ST GEAR TO NEUTRAL AND CLUTCH RELEASED WHILE WAITING FOR LIGHT TO CHANGE. TRANSMISSION FAILED TO SHIFT INTO 1ST GEAR TO MOVE OFF WITH DEPARTING TRAFFIC, RESULTED IN TWO NEAR REAR END COLLISIONS WITH FOLLOWING CARS. RETURNED TO DEALER FOR 600MI RUN IN SERVICE, FAILURE OF MECHANIC TO PROPERLY REINSTALL THE ABS BRAKE SENSOR IN THE REAR WHEEL, PINCHED O-RING, CAUSED FINAL DRIVE OIL TO COAT REAR WHEEL, CAUSING PARTIAL LOSS OF CONTROL IN CORNER, NEAR HEAD ON IMPACT WITH OPPOSIT FLOW OF TRAFFIC. I WAS TOLD BY DEALER OWNER AND SALES REPRESENATIVE, AFTER THE SALE, THAT THE FAILURE TO SHIFT FROM NEUTRAL TO 1ST GEAR IS NORMAL, HAPPENS IN SOME BIKES OF THE SAME MODEL AND NOT IN OTHERS, AND WILL DISAPPEAR DURING BREAK IN BY 6,000 MILES. THIS SHOULD HAVE BEEN MADE KNOW PRIOR TO THE SALE. THE DEALERSHIP OWNER CLAIMED SAME OIL LEAK HAPPENED TO HIS BIKE AND HE FIRED THE MECHANIC AND HAD HIS REAR TIRE REPLACED DUE TO OIL IMPREGNATION. THE DEALER PICKED UP THE MOTORCYCLE AT OUR HOME, MADE REPAIRS AND RETURN DELIVERED IT TO OUR HOME. I INSPECTED AND FOUND THE DEALER USE A CAUSTIC CHEMICAL TO CLEAN, WHICH RESULTED IN CHEMICAL ETCHING OF THE PAINT, INTERIOR SURFACE OF THE RIM REVEALED A THIN FILM OF OIL REMAINING ON THE RIM, STREAKS OF FLUID RADIATED FROM THE WHEEL RIM/TIRE JOINT REVEALED THE TIRE HAND NOT BEEN REPLACED AS PROMISED ON THREE OCASSIONS BY THE DEALERSHIP OWNER, THE FLUID RADIATING FROM THE RIM/TIRE JOINT WAS OIL, WHICH COULD HAVE RESULTED IN ANOTHER INCIDENT OF REAR WHEEL TRACTION LOSS. THE DEALERSHIP OWNER AGREED TO BUY BACK THE MOTORCYCLE AND REFUND, WE ARE STILL WAITING FOR RETURNS OF THE $4,902.98 DEPOSITS AND SERVICE FEE PAID. *TR

NHTSA ID

10229199

Incident

May 12, 2008

Mileage

10 mi

I PURCHASED A 2007 R1200RT BMW MOTORCYCLE WITH A SAFETY PACKAGE OPTION THAT INCLUDES A TIRE PRESSURE MONITORING SYSTEM (TPM) THAT WAS TOUTED AND ADVERTISED AS A SAFETY FEATURE TO HELP PREVENT AN ACCIDENT DUE TO A CATASTROPHIC TIRE FAILURE WHILE RIDING. THE SYSTEM HAS NEVER WORKED PROPERLY. THE SYSTEM IS UNABLE TO MAINTAIN A TIRE PRESSURE READING ON THE FRONT TIRE AND CONTINUALLY DROPS OUT AND IS UNREADABLE. THEY HAVE ATTEMPTED TO REPAIR THE PROBLEM ON FOUR (4) SEPARATE OCCASIONS OVER A TWELVE (12) MONTH PERIOD AND THEY HAVE FAILED. THEY HAVE HAD SIMILAR PROBLEMS ON OTHER BIKES AND HAVE REPLACED THE COMPUTER, BUT ON MINE THEY HAVE REFUSED AND ONLY RE-PROGRAMMED THE SYSTEM. WHEN THE SYSTEM WORKS, IT ALLOWS THE RIDER TO MONITOR THE PRESSURE AND IF THERE IS ANY SUDDEN CHANGE IN PRESSURE THE RIDER IS MADE AWARE OF THE DROP TO AVOID AN ACCIDENT. BMW SAYS THAT THEY ARE UNWILLING TO DO ANYTHING ELSE EXCEPT TURN OFF THE TPM SYSTEM. THEY ADVERTISE THE TPM SYSTEM AS PART OF A SAFETY PACKAGE AND YET IT PROVIDES NO MARGIN OF SAFETY AT ALL UNLESS IT WORKS. I HAVE COPIES OF ALL CORRESPONDENCE WITH THE DEALER, AS WELL AS BMW OF NORTH AMERICA. I HAVE COPIES OF ALL WORK ORDERS AS WELL. AT THE VERY LEAST THEY ARE FRAUDULENTLY MIS-REPRESENTING THEIR PRODUCT IN AN EFFORT TO SELL MORE BIKES, AND MORE IMPORTANTLY GIVING PEOPLE A FALSE SENSE OF SECURITY THINKING THE BIKE WILL ALERT THEM TO ANY POTENTIAL TIRE PROBLEMS, WHEN IN FACT IT WILL NOT! SHOULD SOMEONE COUNT ON THE SYSTEM TO ALERT THEM TO A LOSS IN PRESSURE VISUALLY AND THE SYSTEM DOES NOT HAVE A READING WHEN THE FAILURE OCCURS THE CONSEQUENCES COULD BE DISASTROUS ENDING IN DEATH. THIS HAS BEEN GOING ON FOR THE PAST TWELVE (12) MONTHS. *TR

NHTSA ID

10228355

Incident

May 1, 2008

Mileage

780 mi

MOTORCYCLE RAN OUT OF FUEL JUST 9 MILES AFTER LOW FUEL WARNING ILLUMINATED. TRIP COMPUTER INDICATED 34 MILES REMAINING TO EMPTY, AND FUEL GAUGE SHOWED APPROXIMATELY 1/8 TANK. STATED CAPACITY OF TANK IS 4.8 GALLONS, AVERAGE FUEL ECONOMY IS APPROX. 50 MPG ACCORDING TO TRIP COMPUTER. *TR

NHTSA ID

10206258

Incident

Oct 8, 2007

Mileage

3,200 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