2009 BMW R 1200 RT Fuel/propulsion 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.

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.

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

Mileage: 75,600

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.

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.

Mileage: 96,867

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.

Mileage: 55,000

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.

Mileage: 30,000

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

Mileage: 48,832

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

Mileage: 1,700

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.

Mileage: 4,500

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

Mileage: 58,500

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

Mileage: 13,000