2008 BMW R1200 GS: fuel pump failure

Filed Aug 25, 2020 · Fuel system · 34,283 miles · ID

In 2014 there was a bmw recall on the fuel pump and aux pump flange and the previous owner that owned the bike replaced the pump and flange at that time. It is now only 6 years later; last year I paid my local dealer $382 to replace the auxiliary fuel pump and gasket in may of 2019, and currently (august 15, 2020) I am paying $743 to replace the main fuel pump and flange. My questions are: why didn't the 2014 recall solve the initial problem with the cracked and leaking flange and is this going to be a re-occurring problem every 5 to 6 years? The auxilary fuel pump flange and the main fuel pump flange leak was noticible when I first started up my motorcycle. Fuel was standing / present on top of the fuel pump and aux. Fuel pump when I started the bike. I believe that the flange and the quick connect lines are defective on my bike and that this event is going to keep re-occuring every 5 to 6 years. There has been a recall on certain bmw r1200gs motorcycles by bmwusa, but the customer service representative has informed me that my VIN # is not covered under the recall, but he failed to explain why ity wasn't.

Filed Jan 20, 2020 · Fuel system · 20,470 miles · OK

This is a severe fuel leak that was first noticed when riding the motorcycle when I began to smell gas. As soon as I could get it parked, fuel started pouring out of the fuel pump area. I started my motorcycle again and fuel continued to gush out. It appears to be coming from the top of the fuel pump. This exact issue was addressed with a previous recall 13v‑617 which was performed on my motorcycle on 7/2014. However, the exact issue has surfaced 8/2019 again and the dealership refuses to fix the problem a second time. If I hadn't reached my destination when I did, I fear the motorcycle would have burst into flames! I have contacted bmw corporation and they will not get involved and the dealership still refuses to fix the issue that obviously wasn't repaired the first time properly! This occurred on a city street during normal usage. The "fix" is obviously not a "fix" and there are numerous reports on the internet forums complaining of the same thing. I am very lucky it did not catch on fire while I was riding.

Filed Nov 27, 2013 · Fuel system · 11,565 miles · AZ

I smelled gas and found gas leaking from the fuel pump attached to the gas tank. I found cracks on the periphery of the fuel quick-disconnect port.

Filed Sep 15, 2013 · Fuel system · 34,000 miles · VA

High pressure fuel leak at hose connection to fuel pump housing. Plastic fitting cracked and cracks in boss on fuel pump housing. Noticed fuel puddle on floor while motorcycle was idling.

Filed Aug 22, 2013 · Fuel system · 33,850 miles · NM

Fuel tank is leaking at the plastic flanges where the fuel pump resides. This appears to be a recurring problem for this model year and others.

Filed Jul 7, 2013 · Fuel system · 18,000 miles · CA

While cruising at moderate speed on paved surface road first noticed strong gasoline smell, followed in few minutes by soaking of the left leg of the pants with gasoline, and then observed gasoline dripping on the left cylinder head. Stopped, removed left sided cowling to inspect fuel lines and noted steady stream of fuel leaking from fuel pump housing when engine running.

Filed Dec 11, 2012 · Fuel system · 20,000 miles · TX

Fuel pump flange, a plastic part, on the gasoline tank, had a number of cracks. I found the problem through discussions with other motorcyclists. I feel that if I had not checked for the known problem (among the bmw motorcycling community) fuel would have leaked and posed a serious fire problem and possible injury to myself, possibly fatal.

Filed Aug 20, 2012 · Fuel system, Transmission · 36,700 miles · IL

Tl* the contact owns a 2008 bmw r1200 gs motorcycle. While driving approximately 65 MPH, the contact noticed that the final drive unit and drive shaft were leaking a small amount of oil. The rear wheel began to wobble excessively. The vehicle was towed an authorized dealer who replaced one wheel bearing and the seal. The failure recurred and the vehicle was then taken to an independent mechanic where they replaced the final drive unit and the drive shaft. The manufacturer was not notified of the problem. The approximate failure mileage was 36,700. Updated 09/11/12*lj the consumer stated there was an odor of fuel. The technician discovered fuel leaking from the top of the fuel tank. The fuel pump and relay were replaced. Updated 09/11/12

Filed Jul 23, 2012 · Fuel system · 61,500 miles · TX

While riding my motorcycle, I noticed fuel leaking from the front bottom left side of the fuel tank. Fuel was spraying on to my left leg soaking it in fuel. The location of the spray was directly on top of the front left cylinder and exhaust pipe. The potential for a fire was real. After taking it to the dealer ( gulf coast bmw in houston ), they told me that this was a common failure and showed me a sample of the failed part. I was then forced to buy a complete fuel pump assembly as bmw did not sell the fuel pump flange that failed. The flange developed a crack that allowed fuel to escape under high pressure. The parts alone cost over 700 dollars. I consider this a safety issue common to the r series twin cylinder engines. What's worse is that they replaced the failed part with exactly the same thing so now I am waiting for this part to fail again. This is something that could have easily ended tragically. I am worried for the safety of many other riders out there using this motorcycle and thus I am filing this formal complaint. I have notified bmw about this and they just thanked me for informing them - with no further action or relief for having to purchase an entire assembly for which an individual part failed.

Filed Jul 29, 2011 · Fuel system · 22,569 miles · AZ

A plastic flange on the fuel pump cracked allowing fuel to leak. The flange contains an internal thread that secures one of the fuel lines. Several cracks are visible around the circumference of the flange. Cracks, in my opinion, appear to be related to over-torque at assembly and/or material degradation due to the combined effects of exposure to fuel, time and ambient temperature. The fuel pump is located in the fuel tank that is positioned directly above the engine and exhaust pipe. Fortunately the volume of leaked fuel was small (<1 fl oz) and was contained within a depressed cavity on the top of the pump, otherwise it could have dripped onto the hot engine and exhaust header possibly causing a fire.