BMW K1200 S fuel pump problems

Filed Dec 19, 2013 · Fuel system · 21,000 miles · TX

Fuel tank started leaking fuel enough to drip all over engine and exhaust. Was able to stop bike before fire started. Brought bike to dealership and was able to replace. Dealership said that the fuel pump cracked and was leaking under pressure. Seems to be a common issues with all of the 2005-2008 bmw k1200s motorcycles. Bmw dealership has not filled for a recall to fix all the affected motorcycles yet.

Filed Sep 13, 2013 · Fuel system · 21,000 miles · CA

I could smell a very slight hint of raw fuel, first thought it was a fouled spark plug, so I decided to limit use of the bike until I could get the plugs replaced. I was riding the bike to my local storage, less than 3 miles when I stopped at the gate to enter the code I noticed that the smell had become very strong, I pulled up to my unit and notice a large quantity of fluid running out from inside the bike, at first I thought it was coolant then I realized it was fuel and shut the bike down. I called the bmw service center and they were aware of at least two other bikes with a fuel leak issue, I started to research the issue, I found that a female quick disconnect fitting once installed starts to crack the fuel pump flange. I have removed the tank and found severe cracking around the quick disconnect, as it turns out this is a well documented defect by other bmw k1200 s&r bike owners also it seems that bmw is possibly aware of this and have yet to do a recall or service bulletin that I know of, my reasoning for this is that they (bmw) apparently have started to reinforce the opening for that fitting with a metal gusset to prevent the cracking and from what I have read that's how the replacement part comes. I feel pretty lucky that the unit did not catch fire. I have ordered new parts, to the tune of $800.00 that includes a new heat shield because the one on the bike is saturated with fuel. The tank sits directly above the generator, this leak is not static it happens when the unit is under power.

Filed Aug 29, 2013 · Fuel system · 35,130 miles · CO

My motorcycle started leaking gas in the middle of a day ride and progressively got worse, so that by the end of the day, gas was pouring out onto the side of my engine and onto my boot, pant leg and forming a good size puddle on the asphalt where parked. I ended up having to replace the entire fuel pump assembly ($550 for the part, $850 total cost installed). I want bmw USA to recall this part and stand behind their product. There are multiple internet threads of people complaining about this issue. Many bmw owner's lives are at risk of catching on fire. I have spoken with mechanics and they agree, this is a defect in manufacturing.

Filed Feb 6, 2013 · Fuel system · 17,200 miles · TX

The bmw k-series motorcycles have the same problem with cracks in the fuel pump housing that the federal safety agency is investigating for the r-series bikes (investigation: pe 12-036 / investigator: [xxx]). This problem is potentially more serious in the k-series bikes because on the k-series machines the leak is over the cylinder heads where there is a greater danger of fire. Bmw has indicated to me (by phone) that they will not repair this wide-spread defect in their motorcycles that are out of warranty until there is a recall. Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Filed Jan 30, 2013 · Fuel system · 24,000 miles · CA

The gas tank started leaking fuel. There are small cracks around a plastic fitting that is attached to the fuel tank. The fitting is attached to the fuel pump that sits directly above the alternator.

Filed Nov 20, 2012 · Fuel system · 19,000 miles · SC

Fuel pump housing began leaking after a ride. Started dripping gasoline on the left side. I was able to ride to dealership, where fuel pump was replaced. *tr ## VIN failed

Filed Jul 15, 2012 · Fuel system · 14,560 miles · NM

I noticed the smell of fuel in my garage a few weeks ago and thought it was one of three vehicles in it. I went for a ride this past week and after parking it in the garage I notice a pool do fluid under the bike. I stop to take a look and identify the fluid as gasoline. I took it to the dealer and they tell me it is the fuel pump disconnects that are leaking. These cracks are leaking fuel onto the motor and alternator creating a fire hazard! I have no doubt that this would have eventually lead to a fire that most likely would of lead to severe bodily harm or death! I am sure bmw is aware of this problem as they have updated this part on their new bikes but haven't issued a recall. All evidence shows that bmw is aware of these inherent design flaws in this model motorcycle but refuses to issue a recall putting the public as risk! I believe the federal safety agency needs to take action forcing bmw to properly address these known issues."

Filed Feb 23, 2012 · Fuel system · 10,120 miles · TX

My garage interior was found to have a strong odor of gasoline. On inspection of my motorcycle (2006, bmw k1200s) it was found that the gasoline was leaking from cracks in the plastic (at the attachment point surrounding the female quick disconnect) of the fuel pump housing. The fuel pump housing is a separate part that is attached to the fuel tank. When this fuel tank was removed (from the motorcycle) for a closer inspection, it was found that the gasoline leak was located directly over the starter and alternator of this motorcycle (a direct ignition source for the fuel and fumes).

Filed Feb 20, 2012 · Fuel system · 12,200 miles · CT

Crack observed in fuel pump flange (plastic boss) on female fitting. The crack may eventually leak, causing a fire, injury, and/or death to operator.

Filed Oct 19, 2011 · Fuel system · 24,000 miles · OR

The bike had been serviced about 3 weeks before. I was riding a 3 mile trip into town and noticed a strong gasoline smell, thinking it was the car I was behind, however it increased, and when I got to town, it was obvious that it was coming from my m cycle, and had got very strong. I called the service people who came and took it away. There was a flow of fuel under the tank on the inside of the fairing, and the smell was overpowering. (the system is always positive pressure, even when not on, apparently). My mechanic, who used to be lead mechanic at the local bmw m cycle shop discovered that their were four cracks at the base of the flange, where the fuel flows from. It is a critical safety issue, because their is only a thin heat shield separating this from an open alternator, throwing out sparks. The vapor could very easily ignite. It was replaced at my cost, but the cycle is only 5 years old, garaged and only 24000 easy miles, but this failed, and could have exploded, the vapor was that bad. I took it to the local bmw shop, they examined the failed pump, and advised me to contact bmw service. I have emailed them 4 times and called them 4 times since informing them of the problem, but apart from one missed call with them last thursday, I have not heard back from them. Their service is non existent. This is a major safety issue, high pressure fuel vapors, if I was under high touring speed for instance, with the proximity of the alternator could lead to the cycle catching fire, even "blowing up". There were four cracks on the base of the fuel pump flange. I think they want to blame ethanol, the local shop says that is the case, but they had a similar problem with the 1200r series and replaced it with metal instead of plastics. Thank you for your help with this, I am sure others have had this problem, it needs to be recognized and stopped.