2007 BMW R1200 RT Fuel/propulsion System Problems

FUEL GAUGE STOPPED RESPONDING, LEADING TO RUNNING OUT OF FUEL WHILE MOVING ON A CITY STREET. THIS IS A COMMON FAILURE ON MANY BIKE MODELS FROM BMW FROM 2005-2013. I HAVE HAD THIS HAPPEN 1 TIME SO FAR, AND EACH TIME THE FUEL LEVEL MEASURING STRIP IN THE FUEL TANK WAS REPLACED. THIS IS AN UNSAFE CONDITION SINCE LOSS OF ENGINE POWER FROM RUNNING OUT OF FUEL CAN BE QUITE DANGEROUS ON A MOTORCYCLE.

Mileage: 39,287

FUEL GAUGE STOPPED RESPONDING, LEADING TO THE POSSIBILITY OF RUNNING OUT OF FUEL WHILE MOVING. THIS IS A COMMON FAILURE ON MANY BIKE MODELS FROM BMW FROM 2005-2013. I HAVE HAD THIS HAPPEN 2 TIMES SO FAR, AND EACH TIME THE FUEL LEVEL MEASURING STRIP IN THE FUEL TANK WAS REPLACED. THIS IS AN UNSAFE CONDITION SINCE LOSS OF ENGINE POWER FROM RUNNING OUT OF FUEL CAN BE QUITE DANGEROUS ON A MOTORCYCLE.

Mileage: 49,701

FUEL GAUGE STOPPED RESPONDING, LEADING TO THE POSSIBILITY OF RUNNING OUT OF FUEL WHILE MOVING. THIS IS A COMMON FAILURE ON MANY BIKE MODELS FROM BMW FROM 2005-2013. I HAVE HAD THIS HAPPEN 3 TIMES SO FAR, AND EACH TIME THE FUEL LEVEL MEASURING STRIP IN THE FUEL TANK WAS REPLACED. THIS IS AN UNSAFE CONDITION SINCE LOSS OF ENGINE POWER FROM RUNNING OUT OF FUEL CAN BE QUITE DANGEROUS ON A MOTORCYCLE.

Mileage: 54,020

AFTER SMELLING GAS AFTER A SHORT STOP I DISCOVERED THAT THE FUEL PUMP DISCHARGE FLANGE HAD 7 CRACKS WHERE FUEL WAS LEAKING AND FILLING THE CAVITY AT THE TOP END OF THE FUEL PUMP. AFTER CONDUCTING SOME RESEARCH, I UNDERSTAND THAT THIS IS A KNOWN DEFECT AND SPECIAL AFTER MARKET CLAMPS HAVE BEEN DESIGNED AND SOLD TO MAKE THE REPAIR, AVOIDING A COMPLETE REPLACEMENT OF THE FUEL PUMP. *TR

Mileage: 63,000

RIDING MY 40 MILES HOME, I KEPT SMELLING GASOLINE BUT IT WAS CONGESTED SO I DISMISSED IT. GOT HOME AND DROVE INTO THE GARAGE AND A BIG PUDDLE OF GASOLINE SPLASHED ONTO THE GROUND FROM UNDER MY LEFT FENDER FROM MY 2007 BMW RT1200. UPON EXAMINATION, I DISCOVERED THAT THE PLASTIC TOP OF THE FUEL PUMP HAD CRACKED IN SEVERAL PLACES AROUND WHERE THE QUICK DISCONNECT FITTING GOES FOR THE PRESSURE LINE. NOT ONLY THAT BUT THE FITTING IS ALSO MADE OF PLASTIC AND HAD ALSO CRACKED IN THE THREAD AREA. *TR

THE PLASTIC CONNECTION FOR THE FUEL PUMP CRACKED AND STARTED TO LEAK FUEL. THIS IS A FIRE HAZARD. I LOOKED ON LINE AND SEE THIS IS A PROBLEM ON BMW MOTORCYCLE'S. THE FUEL LEAKS ONTO THE HOT ENGINE AND COULD CAUSE A FIRE WHILE RIDING. THIS IS A FACTORY DEFECT AND ALL BMW MOTORCYCLE SHOULD BE RECALLED BEFORE SOMEONE IS INJURED. *TR

Mileage: 29,100

FITTING AT TOP OF FUEL PUMP ASSEMBLY WAS LEAKING (STREAM OF GAS) GAS ONTO THE GAS TANK AND DOWN ONTO THE LEFT CYLINDER. UPON STARTING THE BIKE , IN LESS THAN A MINUTE THERE WAS A FIVE FEET PUDDLE OF GAS ON THE GROUND. AT REST THE GAS IS POURING ONTO THE LEFT CYLINDER AND I ASSUME WOULD BE SPRAYING ON THE DRIVER AND PASSENGER AT SPEED. AFTER REMOVING THE PANELS TO FIND THE LEAK. THERE WERE SEVERAL CRACKS ON THE FEMALE FITTING SIDE OF THE CONNECTOR OF THE HIGH PRESSURE FUEL LINE. WHERE THE HOSE GOES INTO THE FUEL PUMP ASSEMBLY. SCARY TO THINK IF THIS HAD HAPPENED ON THE ROAD. THE LEAST PROBLEM WOULD BE BEING STRANDED. WORST CASE IF GASOLINE WAS SPRAYED ONTO THE DRIVER AND PASSENGER AND WERE TO IGNITE. *TT

Mileage: 33,000

RIDING TO WORK I NOTICED THE SMELL OF GAS - I PARKED THE BIKE AND NOTICED A STEADY OF GASOLINE DRIPPING OUT FROM UNDER THE LEFT FRONT FAIRING (PLASTIC GAS TANK AND FUEL PUMP ARE BEHIND THE LEFT FAIRING). I REMOVED THE VARIOUS FAIRING PARTS AND NOTICED POOLING OF GASOLINE IN THE RESERVOIR ON TOP OF THE FUEL PUMP FLANGE. I DRIED OUT THE TOP OF THE FLANGE AND TURNED THE KEY BACK ON TO ENGAGE THE FUEL PUMP AND DISCOVERED SEVERAL AREAS WHERE THE GASOLINE WAS SPRAYING FROM THE HIGH PRESSURE, 90 DEGREE GAS LINE BELOW THE BASE OF THE MALE CONNECTOR AND ONLY ON THE SHROUD OF THE FEMALE CONNECTION - BOTH THE 90 DEGREE MALE SIDE AND THE CONNECTING LINE WERE WHOLLY INTACT AND SEATED FULLY INTO THE CONNECTION. I DISCONNECTED THE LINE AND REMOVED THE MALE CONNECTOR AND DISCOVERED MULTIPLE CRACKS AROUND THE SURFACE OF THE FEMALE RECEPTOR THAT PASSED INTO THE THREADED AREA OF THE FLANGE (WHICH ALLOWED GAS TO SPRAY OUT WHEN IT WAS UNDER PRESSURE). THE BIKE IS BACK HOME AND INOPERABLE NOW - THE BIKE AS MENTIONED ABOVE, IS A 2007 BMW R1200RT WITH JUST OVER 21,000 MILES ON IT. *TR

Mileage: 20,100

SIRS, I AM THE ORIGINAL PURCHASER/OWNER OF A BMW R1200RT MOTORCYCLE, VIN# [XXX]. I HAVE HAD TO REPLACE THE FUEL GAUGE SENSOR (PART # 16147675547 - SENSOR AND # 16117677883 - GASKET) THREE TIMES ALREADY. NOW IT HAS FAILED AGAIN. THIS IS THE 4TH TIME IT HAS NEEDED TO BE REPLACED IN 6 YEARS. I CONTACTED MY DEALER (BMW MOTORCYCLES OF COUNTRYSIDE IL) AND SPOKE WITH SERVICE MANAGER [XXX]. [XXX] INFORMED THAT MY LAST FUEL SENSOR REPLACEMENT WAS 27 MONTHS AGO AND THEREFORE IT WILL NOT BE COVERED UNDER WARRANTY (24 MONTH), DESPITE IT HAVING FAILED AND BEEN REPLACED MULTIPLE TIMES AND DESPITE THE FACT THAT THE MOTORCYCLE HAS LESS THAN 14,000 MILES ON IT. HE THEN ESTIMATED IT WOULD COST ME $350 TO REPLACE THE SENSOR. IF THIS WAS THE FIRST TIME I HAD TO REPLACE THE SENSOR, I WOULD UNHAPPILY PAY THE $350 AND ATTRIBUTE IT TO THE MOTORCYCLE BEING 7 YEARS OLD AS THE MILEAGE IS NEGLIGIBLE. BUT THIS IS NOT THE CASE. THIS PART HAS REPEATEDLY FAILED. [XXX] ACKNOWLEDGED THAT THIS IS A WIDESPREAD AND RECURRENT PROBLEM. MY OWN RESEARCH INDICATES THAT MULTITUDES OF BMW R1200 MODEL MOTORCYCLE OWNERS HAVE ALSO BEEN EXPERIENCING MULTIPLE AND REPETITIVE FUEL SENSOR FAILURES FOR MANY YEARS. THIS ISSUE IS DOCUMENTED UNDER NHTSA ID # 10033130 AND BMW SERVICE BULLETIN NO. SIB-16-02-09. THIS R1200RT IS THE MOST EXPENSIVE MOTORCYCLE I HAVE EVER PURCHASED. I FIND IT UNCONSCIONABLE THAT BMW EXPECTS ME TO PAY THE FULL REPLACEMENT COST OF A PART THAT HAS REQUIRED MULTIPLE REPLACEMENTS OVER THE COURSE OF 14,000 MILES, A PART THAT OBVIOUSLY IS THE SUBJECT OF AN INHERENT DESIGN/MANUFACTURING FLAW. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

Mileage: 10,000

RIDING AT ABOUT 50 MPH, MY PASSENGER ASKED TO PULL OVER, "WE ARE LEAKING SOMETHING". I PULLED OVER AND INSPECTED THE BIKE, WE WERE LEAKING FUEL FROM THE FUEL PUMP. FUEL WAS LEAKING DOWN THE FARING & ON TO MY LEFT PANT LEG AND BOOT. I IMMEDIATELY TOOK THE BIKE IN TO THE BMW MOTORCYCLE SHOP FOR INSPECTION & REPAIR. *TR

Mileage: 7,500

YET ANOTHER FUEL LEVEL SENSOR STRIP [FUEL GAUGE] FAILURE. THIS IS NUMBER 6. NOW NO LONGER COVERED AND COST $350 TO REPLACE AT THE DEALER - 250 MILES FROM MY HOME. I THINK THIS IS A SAFETY ISSUE BECAUSE HERE IN THE WESTERN US WHERE IT'S POSSIBLE TO TRAVEL OVER 100 MILES WITHOUT SEEING ANOTHER SMILING FACE, RUNNING OUT OF FUEL IS A SERIOUS THREAT TO YOUR SAFETY. *TR

Mileage: 92,841

WHILE I WAS BACKING MY MOTORCYCLE INTO THE GARAGE I SMELLED A STRONG ODOR OF GASOLINE. AS I DISMOUNTED I NOTICED A LIQUID DRIPPING ON THE GROUND NEXT TO THE LEFT EXHAUST PIPE WHICH TURNED OUT TO BE GASOLINE. I REMOVED THE BODY PANELS TO INVESTIGATE AND FOUND A PUDDLE OF FUEL ON TOP OF THE FUEL PUMP ASSEMBLY. FURTHER INVESTIGATION REVEALED FUEL LEAKING FROM THE BOSS THAT HOLDS THE FEMALE FUEL LINE QUICK DISCONNECT. I REMOVED THE FEMALE QUICK DISCONNECT AND REAPPLIED FUEL RESISTANT SEALANT TO IT AND LET IT SIT OVERNIGHT, THINKING THAT WAS THE PROBLEM. I RECONNECTED THE FUEL LINE AND PRESSURIZED THE SYSTEM. IT STILL LEAKED ONLY WORSE NOW. WHEN I ATTEMPTED TO TIGHTEN THE FITTING A BIT GAS ACTUALLY SQUIRTED OUT OF THE JOINT BETWEEN THE FITTING AND THE BOSS. THIS CAUSED ME TO INVESTIGATE FURTHER AND DISCOVER THAT THE WERE 4 TO 5 SMALL CRACKS IN THE BOSS ON THE FUEL PUMP ASSEMBLY WHERE THE FUEL PRESSURE LINE FEMALE QUICK DISCONNECT SCREWS IN. BEING THAT THE FUEL PUMP ASSEMBLY SITS ABOUT THE LEFT EXHAUST PIPE WHERE IT COMES OUT OF THE CYLINDER HEAD A GAS LEAK FROM THIS AREA IS A FIRE HAZARD. I SHUDDER TO THINK OF WHAT WOULD HAVE HAPPENED IF ONE OF THOSE DROPS OF GASOLINE HAD DRIPPED ON MY EXHAUST PIPE. *TR

Mileage: 36,000

DURING ROUTINE SYSTEMS CHECK, DISCOVERED THAT THE TOP OF THE FUEL PUMP HOUSING (SPECIFICALLY THE RIDGE AT THE BASE OF FUEL LINE DISCONNECT) HAD DEVELOPED NUMEROUS CRACKS AND NO LONGER APPEARS SAFE, ALLOWING FUEL TO LEAK. *TR

Mileage: 40,000

CRACKED BOSS/MOLDED FITTING ON FUEL PUMP/SENDING UNIT ON FUEL TANK, LEAKING FUEL. *TR

Mileage: 50,000

CRACKS EXIST ON FUEL PUMP FLANGE IDENTICAL TO THOSE REPORTED IN PE12-036. THERE ARE NUMEROUS CRACKS AROUND THE FUEL PUMP FLANGE THAT COULD LEAD TO FAILURE/FUEL LEAK. *TR

Mileage: 18,000

WHILE PERFORMING MAINTANANCE ON MY MOTORCYCLE,I FOUND DEEP CRACKS IN THE FUEL PUMP BOSS WHERE THE HIGH PRESSURE FUEL LINE ATTACHES. IF THE CRACKS BECOME ANY DEEPER,FUEL WILL LEAK AND SPRAY ONTO MY ENGINE AND EXHAUST. *TR

Mileage: 13,000

I WAS RIDING AT NIGHT, SUDDENLY SAW SMOG COMING FROM THE FRONT OF MOTORCYCLE AND GAS ODOR AND FELT A WET LEFT LEG AND SHOE, PULL ASIDE AND PARK NOTICING ABOUT A 1/4 GALLON OF FUEL SPILL, AFTER FEW MINUTES MY LEFT HAND, SHOULDER AND NECK JUST BELOW MY HELMET START TO FEEL IRRITATION ON SKIN A BURN FEELING, AFTER REMOVING FAIRINGS FOUND OUT A CRACKED FUEL PUMP AND LEAKING QUICK DISCONNECT FITTING AT HIGH PRESSURE. IN CASE OF FIRE THE POOR FUEL PUMP DESIGN PUT MYSELF IN A REAL HAZARDOUS SITUATION. *TR

Mileage: 49,511

TRAVELING ON I-44 EAST OF JOPLIN MO. SIGNIFICANT ODOR OF GASOLINE. FOUND A SAFE PLACE TO PULL OFF HIGHWAY AND SAW FUEL DRIPPING FROM UNDER THE LEFT FAIRING PANEL. REMOVED THE PANEL TO FIND PUDDLES OF GAS IN THE FAIRING RECESS AND THE FUEL PUMP RECESS. WIPED IT ALL UP AND TURNED ON THE KEY, WHICH STARTED THE PUMP AND A STRONG STREAM OF FUEL WAS PUMPED OUT FROM A SERIOUS CRACK IN THE FUEL PUMP PLATE AT THE FUEL LINE FITTING. THE MOTORCYCLE WAS UNSAFE TO RIDE SO I CALLED FOR A TRAILER, TRAILERED THE BIKE TO KANSAS CITY, MO AND ENGLE MOTORS. THE ENTIRE FUEL PUMP ASSY HAD TO BE REPLACED AT A COST OF $621.52. THERE IS NO QUESTION I WAS VERY LUCKY THE MOTORCYCLE DIDN'T CATCH FIRE WHILE I WAS RIDING IT. I CALLED AND FILED A COMPLAINT TO BMW WITH NO RESPONSE. I HAVE RECEIPTS TO PROVE THE FAILURE AND WITNESSES. BMW NEEDS TO OWN THIS FAILURE AND RECALL ALL THESE MACHINES TO INSURE NO ONE DIES AS A RESULT OF THIS. CALLING THIS A FIRE HAZARD IS UNDERSTATING THE PROBLEM. *TR

Mileage: 82,474

AS I WAS DOING ROUTINE MAINTENANCE, I NOTICED SEVERAL SMALL CRACKS ON THE "FLANGE" WHERE THE QUICK DISCONNECT EXITS THE TANK. I USED A RING CLAMP TO CLOSE THE CRACKS. I BELIEVE THIS TO BE POTENTIALLY VERY DANGEROUS, SINCE LEAKING GASOLINE COULD EASILY RUN DOWN THE OUTSIDE OF THE TANK AND END UP ON HOT ENGINE/EXHAUST PARTS, CAUSING A FIRE... *TR

Mileage: 29,500