2007 BMW R1200 S

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 contact owns a 2007 BMW R 1200S Motorcycle. The contact stated while riding at approximately 35 MPH, there was gasoline leaking from under the fuel tank onto the cylinder head. The contact stated that there were no warning lights illuminated. The contact had the motorcycle towed to a local dealer, where it was diagnosed and determined that the fuel pump needed to be replaced. The motorcycle was not repaired. The manufacturer was not informed of the failure. The contact had researched online and related the failure to NHTSA Campaign Number: 13V617000 (Fuel System, Gasoline). The failure mileage was approximately 70,000. The contact stated the fuel pump was cracked and had it replaced on 5/29/2024 and requesting to be reimbursed as this was a recall. The contact called BMW inquiring about the recall but was informed there was no recall at this time.

NHTSA ID

11591685

Incident

May 13, 2024

Mileage

70,000 mi

FUEL LEAK AT HOUSING ON LEFT SIDE OF FUEL TANK. IS CRACKED AROUND FLANGE THAT HOLDS THE QUICK DISCONNECT ON THE PRESSURE LINE. I REMOVED THE FAILED PART, TOOK IT TO MY LOCAL DEALER WERE THEY QUOTED ME 491 US DOLLARS FOR THE REPLACEMENT. THE DEALER (A & S BMW, ROSEVILLE, CA) DIDN'T INFORM ME OF THE KNOWN ISSUES OR THE AVAILABLE AFTERMARKET FIX. I ATTEMPTED TO REPAIR IT MYSELF WITH JB WELD. IT DIDN'T WORK. NOW I MAY HAVE RUINED THE PART TO THE POINT THAT THE AFTERMARKET FIX ( HTTP://WWW.BEEMERBONEYARD.COM/RK12FUELPMPCLMP.HTML ) WON'T WORK. BMW IS PROFITING ON THIS DESIGN FAULT, THEY WON'T EVEN SELL THE FAULTY PART ALONE, YOU ARE FORCED TO BUY THE WHOLE ASSEMBLY INCLUDING THE FUEL PUMP. *TR

NHTSA ID

10544699

Incident

Sep 15, 2013

Mileage

32,000 mi

I STOPPED AT A STOP-SIGN NEAR HOME. FUEL SPRAYED ALL OVER MY LEFT LEG. IT TURNED OUR MY FUEL PUMP CRACKED. *TR

NHTSA ID

10485452

Incident

Sep 9, 2012

Mileage

12,000 mi

REF: 2007 BMW R1200GS ADVENTURER I PURCHASED THIS MOTORCYCLE AT MILLER BMW OF TALLAHASSEE-FL, ON MARCH 2007. IN APRIL THIS YEAR AND IN FIVE DIFFERENT OPPORTUNITIES THIS MACHINE HAS SHUT DOWN WHILE DRIVING FOR NO APPARENT REASON. ALSO; ONE ADDITIONAL TIME THIS PROBLEM HAPPENED WHILE IN THE DEALER FOR SERVICE. ?ON APRIL 07 ABOUT A MONTH AFTER THE PURCHASE WHILE RIDING IN SR 59 (JEFFERSON FL) AT ABOUT 40 MPH THE MACHINE STALLED, PRODUCING AN ABRUPT REDUCTION IN VELOCITY, I CALLED MILLER BMW AND BASICALLY THEY TOLD ME THAT THEY WERE UNABLE TO HELP ME AND I SHOULD CALL BMW ROAD ASSISTANCE. ROAD ASSISTANCE NEVER CAME, AND AFTER MORE THAN FOUR HOURS ON THE SIDE OF THE ROAD. ?LATER ON, AND AFTER PICKING THE BIKE FROM SERVICE AT MILLER BMW I WAS COMING TO A TRAFFIC LIGHT IN THOMASVILLE ROAD TALLAHASSEE, SUDDENLY THE BIKE STALLED AGAIN, HAVING THE FOLLOWING TRAFFIC TO STOP IN ORDER TO AVOID A COLLISION. AGAIN, I CALLED MILLER BMW, AND AGAIN THEY SUGGESTED CALLING BMW ROAD ASS. WITH MY PAST EXPERIENCE, I DECIDED TO WAIT, AN ABOUT HALF HOUR LATER THE BIKE STARTED AGAIN. THIS WAS A SECOND CLOSE CALL. ?THE THIRD TIME I WAS COMING HOME ON SR 158A AT ABOUT 50 MPH, AND AGAIN THE BIKE STALLED, THE SPEED DROPPED IMMEDIATELY. HOPEFULLY NOTHING HAPPENED. ?THE FOURTH TIME, I WAS TAKING THE BIKE TO MILLER BMW FOR SERVICE. I TOOK IT OUT OF THE GARAGE, 50 YARDS LATER IT STALLED AGAIN. I CALLED MILLER BMW AND REPORTED THE PROBLEM ?LAST SATURDAY WHILE IN A RAVINE IN THE NORTH SIDE OF LAKE MICCOSOUKEE, AND FAR AWAY FROM ANY MAIN ROAD THE BIKE STALLED AGAIN. I CALLED MILLER BMW, THEY TROUBLESHOOT THE BIKE OVER THE PHONE, AND AGAIN THEY SUGGESTED CALLING BMW ROAD ASS. I WAILED FOR ASSISTANCE UNTIL 7PM, THEN AFTER WALKING FOR MILES, I WAS ABLE TO GET SOME HELP AND ARRIVE AT HOME BY MIDNIGHT. THIS MACHINE HAS BEEN TAKEN FOR THIS PROBLEM TO THE BMW DEALER ON MORE THAN FOUR OPPORTUNITIES, AND WITHOUT ANY RESULTS. *TR

NHTSA ID

10211764

Incident

Dec 8, 2007

Mileage

120 mi

TL*THE CONTACT OWNS A 2007 BMW R1200 S. THE CONTACT STATED THAT THE HORN IS INADEQUATE. HE HAS NOTIFIED THE DEALER AND THE MANUFACTURER, BUT THEY ARE NOT TAKING ANY ACTION. THE HORN ALERT IS WEAK AND BARELY AUDIBLE, WHICH CAN BE VERY HAZARDOUS. HE STATED THAT THE ELECTRICAL SYSTEM HAS BEEN REDESIGNED, THEREFORE THE VEHICLE IS ONLY EQUIPPED FOR THIS PARTICULAR HORN. THE POWERTRAIN WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 800.

NHTSA ID

10195685

Incident

Jun 1, 2007

Mileage

800 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.

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