2005 BMW R1200 GS Fuel/propulsion System Problems

TL* THE CONTACT OWNS A 2005 BMW R1200 GS. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, FUEL HAD LEAKED FROM THE FUEL PUMP FLANGE AND SPRAYED ONTO THE RIDERS LEG AND PARTS OF THE MOTORCYCLE. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER AND AN UNKNOWN LOCAL DEALER WERE NOTIFIED OF THE FAILURE BUT NO ASSISTANCE WAS OFFERED. THE CONTACT WAS INFORMED THAT THE MOTORCYCLE WAS NOT INCLUDED IN THE NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM) ALTHOUGH THE MOTORCYCLE HAD EXPERIENCED THE SAME FAILURE LISTED IN THE RECALL. THE FAILURE MILEAGE WAS 24,000.

Mileage: 24,000

FUEL LEAKING AT THE FUEL PUMP FLANGE AS WELL AS AT THE SUCTION PUMP FLANGE AROUND THE BASE OF THE QUICK DISCONNECT FITTING.

Mileage: 34,210

FUEL PUMP FLANGE CRACKED AT FUEL PUMP OUTPUT CONNECTOR AND FUEL SPRAYED OUT UNDER PRESSURE. PRESSURIZED FUEL SPRAYED ON LEG AND HIT HOT ENGINE EXHAUST. WAS ABLE TO CUT OFF ENGINE AND FUEL PUMP BEFORE A FIRE STARTED. HAD TO WAIT SEVERAL HOURS BEFORE HELP ARRIVED AND TRUCKED BIKE HOME. *TR

Mileage: 73,388

FAULTY FUEL STRIP GAS GAUGE WILL SHOW 1/2 TANK, BUT TANK MAY BE FULL OR EMPTY, OR SOMEWHERE IN BETWEEN. LIKEWISE, GAS GAUGE MAY SHOW FULL, BUT TANK MAY BE CLOSE TO EMPTY. THE FUEL STRIP DOES NOT CORRECTLY DISPLAY THE AMOUNT OF FUEL IN THE TANK. *TR

Mileage: 45,000

STOPPED AFTER RIDING TO WORK, NOTICED FUEL SMELL, LOOKED CLOSER, GAS WAS DRIPPING ON HOT EXHAUST PIPE. TURNS OUT THE FUEL LINE PLASTIC QUICK DISCONNECT THREADED BOSS ON THE FUEL TANK WAS CRACKED ENOUGH THAT GAS LEAKS OUT WHEN THE FUEL PUMP IS RUNNING. JUST NOW REPORTING ALTHOUGH IT FIRST HAPPENED YEARS AGO. TRIED VARIOUS REPAIRS THAT WERE ONLY TEMPORARILY EFFECTIVE BEFORE REPLACING THE ENTIRE FUEL PUMP ASSY AND REINFORCING THE BOSS WITH AN AFTERMARKET SPECIALTY CLAMP DESIGNED FOR THIS WELL KNOWN FAILURE. *TR

Mileage: 18,000

CRACKS HAVE BEEN FOUND IN THE FUEL LINE INPUT FLANGE @ FUEL PUMP AND THE RETURN FUEL FLANGE. *TR

Mileage: 45,454

THE FUEL PUMP FITTING CRACKED WHILE I WAS RIDING ON THE HIGHWAY. THIS RESULTED IN FUEL SPRAYING ON ME AND DRIPPING ONTO THE ENGINE WHEN I STOPPED. THE FITTING AND THE FLANGE ARE BOTH MADE OF A PLASTIC MATERIAL. THE THREADS ARE NPT TYPE AND AS THE FITTING IS SCREWED INTO THE FUEL PUMP FLANGE THE FIT GETS TIGHTER. THIS DESIGN WILL EVENTUALLY RESULT IN CRACKING. THIS IS WHAT HAPPENED TO THE PLASTIC FITTING WHICH I REPLACED WITH A METAL ONE. THIS WILL NOT SOLVE THE PROBLEM BECAUSE THE FLANGE IS LIKELY TO CRACK BECAUSE OF THE DESIGN RESULTING IN ANOTHER FAILURE. THIS TYPE OF FAILURE CAN EASILY RESULT IN A FIRE. *TR

Mileage: 25,000

DURING SERVICE, TECH NOTICED A CRACK IN THE FUEL PUMP HOUSING. BIKE IS UNSAFE TO DRIVE DUE TO RISK OF FUEL LEAK AND FIRE HAZARD. THIS PROBLEM IS WELL DOCUMENTED AND COULD POTENTIALLY LEAD TO LOSS OF LIFE OR SEVERE BURNS. RECOMMEND RECALL ON THIS PART. *TR THE ISSUE IS SO WELL KNOWN, ONLINE PARTS STORES ARE SELLING A PARTS FIX. REQUEST REASON WHY RECALL HAS NOT BEEN ISSUED.

Mileage: 60,500

AFTER FILLING UP ON FUEL AND DRIVING HOME (LESS THAN FIVE MILES), I PARKED THE MOTORCYCLE. LATER IN THE DAY, I NOTICED FUEL ON THE ASPHALT BENEATH THE BIKE AND LEAKING FROM THE FUEL PUMP, DOWN ONTO THE ENGINE, LEFT EXHAUST PIPE AND OTHER PARTS OF THE FRAME. FURTHER INSPECTING, I FOUND FUEL POOLED ATOP THE FUEL PUMP HOUSING. MOPPING UP THE FUEL, I IDENTIFIED A HAIRLINE CRACK IN THE UPPER PLASTIC HOUSING THAT HOLDS THE FUEL PUMP, FUEL PUMP ELECTRONICS AND FUEL LINE CONNECTION. THE FUEL PUMP ELECTRONICS UNIT WAS DAMAGED BY EXPOSURE TO THE FUEL, CAUSING SILICON INSULATION TO CRUMBLE AND FALL AWAY. (EVIDENCE THAT THE LEAK HAD EXISTED FOR SOME TIME, BUT ONLY CAME TO MY ATTENTION AFTER THIS PARTICULAR FILL-UP.) REPLACEMENT PARTS ESTIMATE FROM BMW: $680.34 (INCLUDING TAX, BUT EXCLUDING INSTALLATION.) *TR

Mileage: 127,988

DISCOVERED 12/9/2012. EXTENT OF CRACKING INDICATES THAT THE ISSUE LIKELY BEGAN A NUMBER OF YEARS EARLIER. MY FUEL TANK HAS PLASTIC QUICK DISCONNECT FITTINGS ON LEFT AND RIGHT SIDE. NUMEROUS (8-12) SMALL RADIAL CRACKS HAVE APPEARED IN EACH OF THE QUICK DISCONNECT REINFORCEMENT FLANGES, EXTENDING IN SEVERAL CASES DOWN TO THE TOP OF THE TANK. CONTINUED GROWTH OF THE CRACKS INTO THE THREADED AREA HAVE RESULTED IN FUEL LEAKS ON OTHER BIKES WITH THIS SAME CONFIGURATION (BUT NOT YET ON MY BIKE). BELIEF IS THAT THE COMPOSITE QUICK DISCONNECT EXPANDS DURING PRESSURE CYCLING AND IMPARTS A RADIAL LOAD TO THE PUMP HOUSING QUICK DISCONNECT REINFORCEMENT FLANGE. OVER TIME, THIS PRESSURE CYCLING CAUSES CRACKS TO APPEAR IN THE REINFORCEMENT FLANGE WHICH EVENTUALLY RESULT IN FUEL LEAKS. SEE ODI 10428629 AND CASE [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

FUEL STARTED LEAKING FROM TOP OF GAS TANK , LEAKING FROM CRACKS IN FLANGE CONNECTION VERY UNSAFE FIRE HAZARD. *TR

Mileage: 75,000