2005 BMW R1200 GS

ENGINE AND ENGINE COOLING

ON CERTAIN MOTORCYCLES, EXPOSURE OF THE THROTTLE HOUSING TO ROAD DEBRIS COULD FALL AND BECOME CAUGHT BETWEEN THE THROTTLE-BODY AND THE ENGINE BLOCK.

SERVICE BRAKES, HYDRAULIC

ON CERTAIN MOTORCYCLES, IF CERTAIN PROCEDURES ARE PERFORMED THAT INVOLVES REMOVAL OF THE FRONT LEFT BRAKE CALIPER, THE ABS SENSOR CABLE CAN BE ROUTED INCORRECTLY AND WHEN THE CALIPER IS REINSTALLED, THE SENSOR CABLE CAN COME INTO CONTACT AND RUB AGAINST THE FRONT BRAKE DISC. OVERTIME, IF THE CHAFIN

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

ON CERTAIN MOTORCYCLES, THE INTEGRAL ANTI-LOCK BRAKE SYSTEM (IABS) SENSOR SEALING O-RING CONNECTION AT THE REAR AXLE HOUSING MAY BE DAMAGED. AN OIL LEAK MAY DEVELOP.

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

ON CERTAIN MOTORCYCLES, UNDER RAPID, REPEATED, AND UNUSUALLY HARSH BRAKING, LOSS OF ABS CAPABILITY COULD TEMPORARILY OCCUR.

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

BMW of North America, LLC (BMW) is recalling certain 2009-2011 K1300 (S, GT), 2010-2011 S1000 RR, 2005-2011 R1200 (GS, GS Adventure, R, RT, S, ST), 2006-2010 HP2 (Enduro, Megamoto, Sport), 2005-2008 K1200 (R, R Sport, S, GT), and 2012 K1600 (GT, GTL) motorcycles that were repaired under recall 13V-6

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

ON CERTAIN MOTORCYCLES, AN ADAPTER IN THE REAR BRAKE LINE CONNECTS A RIGID SECTION TO A FLEXIBLE SECTION. IF THE RIGID SECTION IS NOT PROPERLY ENGAGED IN THE ADAPTER, IT IS POSSIBLE FOR A LEAK TO DEVELOP.

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

ON CERTAIN MOTORCYCLES, THE DEFECT INVOLVES A WATER LEAK AROUND THE FUEL PUMP THAT IS INTEGRATED WITHIN THE FUEL TANK. AN O-RING SEAL ATTACHED TO THE PUMP'S ELECTRONIC HOUSING DOES NOT MEET SPECIFICATIONS AND WATER CAN BYPASS THIS SEAL AND CONTACT THE PUMP ELECTRONICS.

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

ABS PUMP FAILURE.

Mileage: 59,000

I EXPERIENCED A 100% NO BRAKES SITUATION COMING INTO A SLOW SPEED 90 DEGREE TURN ON A BACK ROAD. LUCKILY I HADN'T BEEN GOING TO FAST AND WAS ABLE TO DOWN SHIFT AND SCRUB A LITTLE SPEED BUT FORCED WITH ONLY ENGINE BRAKING AND A VERY OLD ASPHALT ROAD COVERED IN GRAVEL I HAD TO LAY IT DOWN TO STOP FROM GOING INTO A 60FT+ RAVINE. I'VE PUT 250-300K OF STREET RIDING UNDER MY BUTT AND THIS IS THE FIRST TIME I'VE LAID A BIKE DOWN. I DID HURT MY LEFT LEG AND I HAVE A HUGE BRUISE THERE NOW AND MY CRASH BARS PREVENTED ANY MAJOR DAMAGE TO THE BIKE BUT IT DID STILL CAUSE ABOUT $500 IN DAMAGES. I'M WELL AWARE OF THE PROBLEMS THAT THE 05-06 SERVO BIKES HAVE HAD WITH BRAKE FAILURE BUT I'VE ALWAYS READ THAT THE RESIDUAL BRAKES ARE STILL THERE IF THE SERVOS FAIL. I CAN ATTEST I HAD ZERO BRAKES! LEVER WENT TO THE BARS AND REAR JUST FELL DOWN AND HAD NOTHING. I'VE ACTUALLY PRACTICE A COUPLE PANIC STOPS WITH THE IGNITION OFF TO EXPERIENCE WHAT JUST THE RESIDUAL BRAKE FEEL LIKE AND I WAS ABLE STOP FAIRL

Mileage: 51,010

UPON REPLACING REAR TIRE AT THE BMW DEALERSHIP, NOTICED A CRACKED REAR WHEEL FLANGE. THESE CRACKS APPEARED ON 4 OF 5 ATTACHMENT POINTS WHERE THE FLANGE BOLTS ONTO THE REAR DRIVE. THIS IS A PART THAT HOLDS THE WHEEL TO THE MOTORCYCLE. SPOKE TO BMW NA AND THEY DO RECOGNIZE THE PROBLEM AS INHERENT DEFECT, AND HAVE NOT RECALLED DESPITE HAVING REDESIGNED THE REPLACEMENT PART SEVERAL TIMES OVER THE LAST FEW YEARS (IMPLIED ADMISSION BY BMW OF THE INHERENT DEFECT DUE TO REDESIGN). THIS IS SAFETY ISSUE RELATED TO AN INHERENT DEFECT OF SAFETY CRITICAL PART - THE REAR WHEEL FLANGE. FAILURE OF THIS PART WHILE THE VEHICLE IS BEING OPERATED MAY CAUSE LOSS OF REAR BRAKE FUNCTION, LOSS OF STEERING ABILITY, SUDDEN SEIZURE OF REAR WHEEL, AND/OR POSSIBLE LOSS OF REAR WHEEL. THIS MAY LEAD TO SERIOUS INJURY AND EVEN DEATH. *TR

Mileage: 62,000

UPON REPLACING REAR TIRE AT THE BMW DEALERSHIP, NOTICED A CRACKED REAR WHEEL FLANGE. THESE CRACKS APPEARED ON 4 OF 5 ATTACHMENT POINTS WHERE THE FLANGE BOLTS ONTO THE REAR DRIVE. THIS IS A PART THAT HOLDS THE WHEEL TO THE MOTORCYCLE. SPOKE TO BMW NA AND THEY DO RECOGNIZE THE PROBLEM AS INHERENT DEFECT, AND HAVE NOT RECALLED DESPITE HAVING REDESIGNED THE REPLACEMENT PART SEVERAL TIMES OVER THE LAST FEW YEARS (IMPLIED ADMISSION BY BMW OF THE INHERENT DEFECT DUE TO REDESIGN). THIS IS SAFETY ISSUE RELATED TO AN INHERENT DEFECT OF SAFETY CRITICAL PART - THE REAR WHEEL FLANGE. FAILURE OF THIS PART WHILE THE VEHICLE IS BEING OPERATED MAY CAUSE LOSS OF REAR BRAKE FUNCTION, LOSS OF STEERING ABILITY, SUDDEN SEIZURE OF REAR WHEEL, AND/OR POSSIBLE LOSS OF REAR WHEEL. THIS MAY LEAD TO SERIOUS INJURY AND EVEN DEATH. *TR

Mileage: 62,000

UPON REPLACING REAR TIRE AT THE BMW DEALERSHIP, NOTICED A CRACKED REAR WHEEL FLANGE. THESE CRACKS APPEARED ON 4 OF 5 ATTACHMENT POINTS WHERE THE FLANGE BOLTS ONTO THE REAR DRIVE. THIS IS A PART THAT HOLDS THE WHEEL TO THE MOTORCYCLE. SPOKE TO BMW NA AND THEY DO RECOGNIZE THE PROBLEM AS INHERENT DEFECT, AND HAVE NOT RECALLED DESPITE HAVING REDESIGNED THE REPLACEMENT PART SEVERAL TIMES OVER THE LAST FEW YEARS (IMPLIED ADMISSION BY BMW OF THE INHERENT DEFECT DUE TO REDESIGN). THIS IS SAFETY ISSUE RELATED TO AN INHERENT DEFECT OF SAFETY CRITICAL PART - THE REAR WHEEL FLANGE. FAILURE OF THIS PART WHILE THE VEHICLE IS BEING OPERATED MAY CAUSE LOSS OF REAR BRAKE FUNCTION, LOSS OF STEERING ABILITY, SUDDEN SEIZURE OF REAR WHEEL, AND/OR POSSIBLE LOSS OF REAR WHEEL. THIS MAY LEAD TO SERIOUS INJURY AND EVEN DEATH. *TR

Mileage: 62,000

TL* THE CONTACT OWNS 2005 BMW R1200 GS. THE CONTACT STATED THAT WHILE INSPECTING THE MOTORCYCLE, THE CONTACT DISCOVERED THAT THERE WAS A CRACK ON THE REAR WHEEL FLANGE. THE MOTORCYCLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED WITH A FRACTURED WHEEL FLANGE. THE MANUFACTURE WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 47,000.

Mileage: 47,000

I WAS REPLACING MY REAR BRAKE ROTOR. THE ROTOR IS BOLTED TO A PIECE CALLED A FLANGE (PART NUMBER 33117722831) USING 5 BOLTS. I FOUND THAT EACH OF THE 5 BOLT HOLES IN THE FLANGE ARE CRACKED. IF THIS PART WERE TO COME APART WHILE RIDING I THINK IT WOULD CAUSE THE REAR WHEEL TO LOCK UP AND SKID OR POSSIBLY WORSE. THE FLANGE (PART NUMBER 33117722831) IS ALSO PART OF THE POWER TRAIN AND REAR WHEEL DRIVE SYSTEM (ALSO KNOWN AS THE FINAL DRIVE SYSTEM) FOR THE BMW R1200GS MOTORCYCLE. THE BMW MUST KNOW THAT THIS IS A DANGEROUS PROBLEM BECAUSE THEY HAVE REDESIGNED THE PART. SEARCHING THE INTERNET FOR "BMW R1200GS FLANGE CRACK" RETURNS MANY PAGES OF INFORMATION ON THIS PROBLEM. HERE IS A GOOD SUMMARY: HTTP://WWW.MTS1200.INFO/MOTORCYCLEINFO/INDEXE65D.HTML?FA=CONTENTGENERIC.NKYQIUKEVRYEUZUT&PAGEID=360814. *TR

Mileage: 32,390

I WAS REPLACING MY REAR BRAKE ROTOR. THE ROTOR IS BOLTED TO A PIECE CALLED A FLANGE (PART NUMBER 33117722831) USING 5 BOLTS. I FOUND THAT EACH OF THE 5 BOLT HOLES IN THE FLANGE ARE CRACKED. IF THIS PART WERE TO COME APART WHILE RIDING I THINK IT WOULD CAUSE THE REAR WHEEL TO LOCK UP AND SKID OR POSSIBLY WORSE. THE FLANGE (PART NUMBER 33117722831) IS ALSO PART OF THE POWER TRAIN AND REAR WHEEL DRIVE SYSTEM (ALSO KNOWN AS THE FINAL DRIVE SYSTEM) FOR THE BMW R1200GS MOTORCYCLE. THE BMW MUST KNOW THAT THIS IS A DANGEROUS PROBLEM BECAUSE THEY HAVE REDESIGNED THE PART. SEARCHING THE INTERNET FOR "BMW R1200GS FLANGE CRACK" RETURNS MANY PAGES OF INFORMATION ON THIS PROBLEM. HERE IS A GOOD SUMMARY: HTTP://WWW.MTS1200.INFO/MOTORCYCLEINFO/INDEXE65D.HTML?FA=CONTENTGENERIC.NKYQIUKEVRYEUZUT&PAGEID=360814. *TR

Mileage: 32,390

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

SMELLED FUEL, REMOVED LEFT SIDE COVER, SAW TOP OF FUEL PUMP COVERED WITH GAS. IT IS LEAKING FROM THE PLASTIC QUICK DISCONNECT. ALSO SEE CRACKS IN THE FLANGE ON TOP OF FUEL PUMP. THIS IS A FIRE HAZARD, CAUSED BY POOR DESIGN THAT USES TAPERED PIPE THREAD IN PLASTIC. *TT

Mileage: 27,443

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

UPON INSPECTION, I DISCOVERED THAT EACH OF FIVE WHEEL MOUNTING TABS ON THE REAR WHEEL FLANGE IS CRACKED. THIS HAS BEEN REPORTED IN NUMEROUS OTHER BMW R1200GS MOTORCYCLES, IN SOME CASES LEADING TO CATASTROPHIC FAILURE. *TR

Mileage: 130,000

TL* THE CONTACT OWNS A 2005 BMW R1200GS MOTORCYCLE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR UNRELATED MAINTENANCE WHEN THEY NOTICED THAT THE REAR WHEEL FINAL DRIVE WAS SEVERELY WORN. THE PART WAS ORDERED AND THE VEHICLE WAS LATER REPAIRED. THE REAR BRAKE PADS WERE REPLACED DURING THE REPAIR DUE TO AN EXCESSIVE OIL LEAK FROM THE REAR WHEEL. THE DRIVE SHAFT WAS ALSO DAMAGED AND WOULD NEED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 68,000. UPDATED 06/10/13 *BF THE CONSUMER STATED THE FINAL DRIVE SEAL BLEW WHILE DRIVING. THE REAR TIRE WAS COVERED IN OIL. IN ADDITION, THE REAR BRAKE PAD HAD TO BE REPLACE DUE TO OIL DAMAGE. WHILE REPAIRING THE FINAL DRIVE. THE MECHANIC FOUND THE DRIVE SHAFT WAS NOTCHY AND NEEDED TO BE REPLACED.

Mileage: 68,000

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