2006 BMW R1200 RT fuel system problems

FUEL/PROPULSION SYSTEM

TL* THE CONTACT OWNS A 2006 BMW R1200 RT. WHILE DRIVING 55 MPH, THE CONTACT SMELLED FUEL COMING FROM THE FUEL PUMP. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT STOPPED THE VEHICLE AND NOTICED FUEL LEAKING OVER THE ENGINE. THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 13V617000 (FUEL SYSTEM, GASOLINE). THE CONTACT CALLED BMW MOTORCYCLES MCDONOUGH (LOCATED AT 755 INDUSTRIAL BLVD, MCDONOUGH, GA 30253, (770) 957-7404) AND INFORMED THEM OF THE FAILURE. THE MOTORCYCLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 41,109. *LN CONSUMER STATED THIS ISSUE WAS ADDRESSED ONCE IN RECALL 13V617 IN 2014. REPAIR HISTORY INDICATES MY BIKE WAS CHECKED FOR THIS ISSUE BUT THERE IS NO INFORMATION ON WHETHER REPAIRS WERE PERFORMED. GIVEN THE INFORMATION IN THE TECHNICAL DOCUMENT, EITHER THE PUMP WAS REPLACED ENTIRELY OR THERE WAS NOTHING DONE. NO METAL REINFORCING RING WAS PLACED ON THE FUEL PUMP, SO EITHER THE PUMP WAS REPLACED WITH ANOTHER FAULTY PUMP OR NO REPAIRS WERE MADE. THIS RECALL WAS NOT ADDRESSED ON MY BIKE EVEN THOUGH THE BIKE WAS CHECKED. I AM HAVING THE EXACT ISSUE MENTIONED FOR SIEMENS FUEL PUMPS IN BMW MOTORCYCLES UNDER THE RECALL. PHOTOS, FUEL LEAK NHTSA INVESTIGATION, AND 2006 BMW REPAIR HISTORY ATTACHED.

NHTSA complaint #11267990 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

FUEL LEAK: THE PLASTIC AROUND THE FUEL PUMP OUTPUT FITTING IS CRACKED AND LEAKING. MY LEFT LEG WAS COVERED IN GASOLINE AS WELL AS MY LEFT FAIRING.

NHTSA complaint #10625854 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

IN-TANK FUEL PUMP LEAKS FUEL AT THREADED CONNECTION TO OUTLET QUICK-RELEASE FITTING. I PURCHASED AND INSTALLED A REINFORCEMENT CLAMP MADE BY A THIRD-PARTY SUPPLIER AND REINSTALLED THE QUICK-RELEASE FITTING WITH A FUEL-RESISTANT THREAD SEALANT, BUT THE FITTING STILL LEAKS. I'LL TRY ADHESIVE INSTEAD, ON THE ADVICE OF OTHERS WITH THE SAME PROBLEM. FUEL LEAKS ARE NOT ACCEPTABLE ON ANY VEHICLE, PARTICULARLY NOT ON A SUPPOSEDLY HIGH-QUALITY MOTORCYCLE.

NHTSA complaint #10550550 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

I SMELLED FUEL (ON AND OFF) ON THE HIGHWAY ON THE WAY TO WORK. WHEN I CAME TO MY PARKING SPACE, THEN I REALLY SMELLED IT. WHEN I LEANED THE BIKE TO PUT IS ON THE SIDE STAND SOME FUEL DRIPPED OUT FROM UNDER THE COWLING, RIGHT BY THE EXHAUST PIPE. AFTER WORK, IN THE PARKING LOT, I DISASSEMBLED THE COWLING AND FOUND THAT THE BASE OF THE FUEL PUMP ASSEMBLY PACKAGE WHERE THE FUEL LINE CONNECTOR FITTING GOES INTO, WAS CRACKED, (NOT ENOUGH PLASTIC AROUND THE FITTING). I CALLED THE DEALER AND HE KNEW EXACTLY WHAT I WAS REFERRING TO, AND WAS TOLD THE PART WAS $550 BECAUSE IT INCLUDED THE FUEL PUMP (WHICH I DON'T NEED). I DECIDED THAT I WOULD NOT BUY ANOTHER DEFECTIVELY DESIGNED PIECE, SO I GOT A CLAMP AND PUT IT OVER THE CRACKED PART, AND EPOXIED IT. MAKING IT A BETTER DESIGN. THE NEXT DAY, I ALSO WAS TOLD THAT THE NEW PIECE FROM BMW HAS THE SAME SOLUTION TO THE PROBLEM, A STEEL BAND. I DON'T KNOW IF THEIRS IS STAINLESS STEEL LIKE MINE. AT FIRST, I WOULD HAVE SETTLED FOR JUST THE PART I NEEDED, BUT TO BE SOLD THE SAME CRAP PLUS A PART I DIDN'T NEED, I WASN'T GOING TO DO IT. AT THE URGING OF ANOTHER DEALER I CALLED BMW CUSTOMER SERVICE AND THEY SAID THEY DIDN'T CARE ABOUT MY PROBLEM, IN A PROFESSIONAL WAY OF COARSE. I TRY NOT TO PANIC ABOUT SAFETY ISSUES (I AM AN INSPECTOR OF EQUIPMENT IN ANOTHER LINE OF WORK). HOWEVER, THEIR LACK OF CORRECTIVE BACKING OF A BADLY DESIGNED PART CAUSED ME TO FILE THIS COMPLAINT. IT IS AT IT'S CORE A SAFETY ISSUE.

NHTSA complaint #10550138 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

WHILE RIDING MOTORCYCLE NOTED FUEL SMELL AND DISCOVERED LEAKING FUEL FROM CRACKS IN THE FUEL PUMP ASSEMBLY TOP PLATE WHERE THE PLASTIC HIGH PRESSURE LINE QUICK DISCONNECT FITTING SCREWS IN TO THE TAPERED PIPE THREADS OF THE PLASTIC PLATE. NOTED EVIDENCE OF FUEL LEAKAGE POOLING WITH POTENTIAL OF DRIPPING ONTO HOT EXHAUST COMPONENTS. IF FUEL WERE TO BE IGNITED THERE WOULD LIKELY BE A CATASTROPHIC FIRE AND POTENTIAL CRASH. THERE IS ALSO THE POSSIBILITY OF LOSS OF TRACTION FOR THE REAR TIRE DUE TO LEAKAGE ON THE GROUND, ALSO POTENTIALLY LEADING TO A CRASH. I BELIEVE THIS IS A SERIOUS DESIGN SPECIFICATION FLAW THAT MAY OCCUR ON ALL THE MOTORCYCLES SIMILARLY EQUIPPED. I ALSO BELIEVE THIS WARRANTS IMMEDIATE ACTION BY BMW, BOTH FOR MOTORCYCLES THAT HAVE YET TO FAIL, AND FOR THOSE THAT HAVE FAILED AND HAVE BEEN REPAIRED BY THE OWNERS.

NHTSA complaint #10546949 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

GAS LEAKING FROM LEFT SIDE FAIRING AFTER RIDING WITH SMALL SPILL OF GAS ON GARAGE FLOOR. TAKEN TO MORTONS BMW DEALER TODAY WHERE DEFECTIVE O-RING AND CRACKS IN FUEL PUMP FLANGE WERE NOTED. PRIOR # JBN1-18051.

NHTSA complaint #10534549 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

FUEL SMELL ON CLOTHING AND LEAKING FUEL FOUND DRIPPING ON HOT EXHAUST DURING STOP AT GAS STATION TO REFUEL. IMMEDIATELY PUSH MOTORCYCLE TO SAFE AREA AWAY FROM GAS STATION TO ASSESS CAUSE OF LEAK. FOUND MULTIPLE CRACKS IN PLASTIC FUEL PUMP HOUSING FLANGE THAT WHICH THE HIGH PRESSURE FUEL LINE QUICK DISCONNECT THREADS INTO. FUEL WAS POOLING APPROXIMATELY ONE INCH DEEP ON TOP OF THE FUEL PUMP HOUSING AND NEXT TO FUEL PUMP ELECTRICAL CONTROL RELAY AND WIRING. MOTORCYCLE HAD TO BE TOWED 75 MILES TO NEAREST BMW MOTORCYCLE DEALER FOR FUEL PUMP AND HOUSING REPLACEMENT.

NHTSA complaint #10534389 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

FUEL GAUGE SHOWED 1/3 OF TANK OF FUEL REMAINING AND 110 MILES LEFT BEFORE RUNNING OUT OF GAS. BIKE RAN OUT OF GAS WHILE RIDING DOWN HIGHWAY AS TANK WAS EMPTY. WAS ABLE TO PULL OVER TO SIDE OF ROAD SAFELY AND CALL FOR ASSISTANCE. FUEL GAUGE HAS NOT READ ACCURATELY SINCE.

NHTSA complaint #10505404 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

I STARTED THE MOTORCYCLE ENGINE. A FEW SECONDS AFTER IT STARTED, GASOLINE STARTED TO GUSH FROM THE FRONT OF THE BIKE ONTO THE ENGINE. BEFORE I KNEW IT, I WAS IN A PUDDLE OF GASOLINE. I SHUT IT OFF AS SOON AS I REALIZED WHAT WAS HAPPENING. I MOPPED UP THE GASOLINE OFF OF THE FLOOR TO ELIMINATE THE FIRE DANGER. I LOCKED THE STEERING AND PUT THE KEY AWAY AFTER THAT.

NHTSA complaint #10487624 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

THE HIGH PRESSURE OUTLET PORT ON THE FUEL PUMP ASSEMBLY DEVELOPED CRACKS THAT EXTENDED FROM THE OUTSIDE OF THE FEMALE PORTION OF THE OUTLET INTO THE THREADS. THIS ALLOWED GASOLINE TO SPRAY ONTO THE INNER PORTION OF THE BODY MOLDING AND RAN DOWN ONTO THE ENGINE AND THE RIDERS LEG ON THE LEFT SIDE.

NHTSA complaint #10471642 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

ENGINE BEGAN STALLING FREQUENTLY AT END OF RIDING SEASON (FALL 2011) WHEN THE ENGINE WAS AT ITS NORMAL OPERATING TEMPERATURE. ENGINE STALLING OCCURRED WHEN DECELERATING WITH CLUTCH ENGAGED OR AT IDLE, ENGINE WOULD NOT RETURN TO NORMAL IDLE SPEED WITHOUT STALLING. THE ENGINE WAS SERVICED/MAINTAINED BY AN AUTHORIZED LOCAL BMW MOTORCYCLE DEALER ON 3/10/2012 ? 3/13/2012 WITH HOPES THAT ENGINE WOULD RETURN TO NORMAL OPERATING BEHAVIOR FOR THE FOLLOWING RIDING SEASON (2012). THIS SERVICE/ MAINTENANCE INCLUDED BUT WAS NOT LIMITED TO BMW INSPECTION WITH ANNUAL SERVICE, INCLUDES ALL FLUIDS AND VALVE ADJUSTMENT AND THROTTLE BODY SYNCHRONIZATION. BUT ON 5/6/2012 THE BIKE WAS RIDDEN ON ITS FIRST LONG RIDE OF THE SEASON. AFTER RIDING APPROXIMATELY 65 MILES THE BIKE BEGAN TO HAVE THE SAME SYMPTOMS AS DURING THE LAST RIDE IN THE FALL OF 2011. ON 5/8/2012 THE BIKE WAS TAKEN TO THE SAME LOCAL BMW MOTORCYCLE DEALER THAT PERFORMED THE ANNUAL MAINTENANCE IN MARCH. DURING THE WEEK OF 5/15/2012 THE BIKE WAS DIAGNOSED, REPAIRED AND AVAILABLE TO BE PICKED UP ON 5/18/2012. THE DIAGNOSIS FROM THE DEALER'S SERVICE TECHNICIAN IS STATED ON THE SERVICE INVOICE AS FOLLOWS: PLASTIC FUEL CONNECTOR HAD HAIRLINE CRACK CAUSING FUEL CUT RELAY TO NOT ACTIVATE WHEN DECELERATING CAUSING ENGINE TO STALL. UPGRADED PLASTIC FUEL CONNECTOR WITH METAL CONNECTOR. PARTS REPLACED WERE BMW PART NUMBERS: 16 12 1 176 918:HOSE CLAMP 13 53 7 700 800:PLUG (METAL FUEL LINE MALE CONNECTOR) N/A:FUEL HOSE CUT 1FT.

NHTSA complaint #10459714 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

OUTPUT PRESSURE BUNG (PLASTIC) IN FUEL PUMP ASSEMBLY WHERE QUICK DISCONNECT FITTING IS SCREWED IN. THE BUNG DEVELOPED SMALL RADIAL CRACKS THAT BEGAN TO LEAK GASOLINE THAT WOULD DRIP ONTO THE LEFT ENGINE CYLINDER OR ONTO DRIVER'S LEFT LEG WHILE MOVING.

NHTSA complaint #10448216 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

SEVERE DEEP CRACKS ALL AROUND THE PLASTIC COLLAR OF THE OUTPUT PORT OF THE SIEMENS HIGH-PRESSURE FUEL PUMP. FUEL LEAK IMMINENT, WHICH WOULD SPRAY FUEL ALL OVER THE ENGINE. IT'S COMPLETELY HIDDEN BY THE BODYWORK/FARING SO IT WAS LUCKY THAT I NOTICED IT WHILE SERVICING. EXTREMELY DANGEROUS.

NHTSA complaint #10448104 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

HIGH PRESSURE FUEL LEAK WHERE THREADED PLASTIC QUICK DISCONNECT MATES WITH PLASTIC FLANGE ON TOP OF THE FUEL PUMP. PLASTIC FLANGE IS MOLDED INTO THE TOP OF FUEL PUMP AND HAS MULTIPLE HAIRLINE CRACKS. SPRAYED GAS WHILE BIKE WAS IDLING. NO INJURY, BUT DANGEROUS ENOUGH SITUATION TO REPORT. USE OF USED PUMPS IS NOT RECOMMENDED. I FOUND THAT USED PUMPS HAD SIMILAR CRACKING; ONLY OPTION WAS TO HAVE BMW DEALERSHIP REPLACE WITH NEW PUMP.

NHTSA complaint #10435968 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

WHILE RIDING MOTORCYCLE NOTED FUEL SMELL, THEN DISCOVERED LEAKING FUEL FROM CRACKS IN THE FUEL PUMP ASSEMBLY TOP PLATE WHERE THE HIGH PRESSURE LINE QUICK DISCONNECT FITTING SCREWS IN TO THE PLATE. NOTE THAT THE FITTING ITSELF AND THE PLATE ARE BOTH MADE OF PLASTIC, AND THE THREADS ARE TAPERED "PIPE" THREADS. THE EXHAUST SYSTEM RUNS NEARLY DIRECTLY BENEATH THE AREA OF THE LEAK, AND IF THE FUEL WERE TO BE IGNITED THERE WOULD LIKELY BE A CATASTROPHIC FIRE AND POTENTIAL CRASH. THERE IS ALSO THE POSSIBILITY OF LOSS OF TRACTION FOR THE REAR TIRE DUE TO LEAKAGE ON THE GROUND, ALSO POTENTIALY LEADING TO A CRASH. I BELIEVE THIS IS A SERIOUS DESIGN SPECIFICATION FLAW THAT MAY OCCUR ON ALL THE MOTORCYCLES EQUIPED SIMILARLY. I ALSO BELIEVE THIS WARRANTS IMMEDIATE ACTION BY BMW, BOTH FOR MOTORCYCLES THAT HAVE YET TO FAIL, AND FOR THOSE THAT HAVE FAILED AND HAVE BEEN REPAIRED BY THE OWNERS. I HAVE PICTURES AVAILABLE OF THE FAILED AREA, AND HAVE POSTED ABOUT THIS IN THE PAST AT THE FOLLWING LINK. HTTP://BMWSPORTTOURING.COM/UBBTHREADS/UBBTHREADS.PHP?UBB=SHOWFLAT&MAIN=54059&NUMBER=598196#POST598196

NHTSA complaint #10433013 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

TL* THE CONTACT OWNS A 2006 BMW R1200 RT. THE CONTACT STATED THAT THERE WAS AN ABNORMALLY OVERPOWERING ODOR OF GASOLINE FROM THE EXTERIOR OF THE VEHICLE. THE VEHICLE WAS PARKED AND SHUT OFF WHEN HE NOTICED THE ODOR. THE ODOR WAS ALSO PRESENT WHENEVER THE VEHICLE WAS IN OPERATION. THE CONTACT LATER DISCOVERED A PUDDLE OF GASOLINE ON TOP OF THE FUEL PUMP. THE CONTACT WAS ABLE TO LOCATE A LEAK IN THE FUEL PUMP. THE VEHICLE WAS NOT EXAMINED FOR THE CAUSE OF FAILURE. THE CONTACT MADE REPAIRS TO CORRECT THE FAILURE. THE FAILURE MILEAGE WAS 65,000 AND THE CURRENT MILEAGE WAS 77,400.

NHTSA complaint #10356156 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

WHILE RIDING SUDDEN UNEXPECTED ENGINE SHUT DOWN HAS HAPPENED ONCE, 10/31/2009 ENGINE DOES NOT RUN, QUIT WHILE RIDING IN TRAFFIC ON HIGHWAY. WAS ABLE TO COAST OFF ROAD WITHOUT ACCIDENT REPLACED FUEL PUMP CONTROLLER, FOUND FAILED CONTROLLER HAD BEEN CONTAMINATED WITH WATER THAT COLLECTS IN FUEL PUMP ACCESS PLATE. OLD PART IS AVAILABLE.

NHTSA complaint #10290546 — an unverified report by a vehicle owner.