The fuel strip failed on the motorcycle. This is a well known issue with these motorcycle, even by bmw. This could create a serious safety issue if the fuel quantity depletes on a busy interstate or in a busy intersection.
2005 BMW R1200 RT fuel system complaints
Page 2 of 2: complaints 11 to 22 of 22, newest first, as owners wrote them.
I was riding my motorcycle in the right hand lane in a 50mph residential zone in fairly heavy evening traffic when the engine started to severely misfire and stumble / sputter. Luckily I was in the right hand lane because the engine then died and I was able to pull to the side without too much difficulty although the vehicle behind came very close to me since the bike so rapidly slowed without my brakelight on to indicate a slow down. The bike would not restart and I had a friend trailer it to my house, since this was at night and the dealership was closed. Upon investigation, I found the gas tank was bone dry, which came as a huge surprise since the gas gauge showed a 1/4 tank remaining and over 100 miles to go before empty. I put a gallon of gas in it and it started right up. I took it to the dealer in the morning and they had to replace the fuel sensor film strip to the tune of $265.68, which my extended warranty covered except for the $50 deductible. I consider myself very lucky that this did not happen on the freeway in heavy traffic as the outcome might have been radically different.
This failure is not limited to the 2005 bmw r1200rt. The same fuel pump is used from 2005-2009 in the rt1200rt and r1200gs. The fuel pump housing high-pressure fuel quick disconnect reinforcement flange cracks under high pressure cycling and leaks, sending raw fuel down the left fairing in close proximity of the vehicles left exhaust pipe and ignition system components. The motorcycle fairing effectively captures the fuel vapors creating a significant risk for fire. In addition, leaking fuel, streaming along the left fairing is exhausted on the riders left leg, creating significant risk for the rider even after dismounting the vehicle. Consequences of failure the combination of high fuel pressure and negligent design create substantial risk for riders of the impacted vehicles. Consequences of this failure are outlined below: 1. Riders become fuel soaked as fuel leaks down the left fairing and then is forced by fairing airflow dynamics on to the riders left leg. 2. Fuel vapors, captured by the fairing and heated by the exhaust pipe become extremely volatile and could lead to a fire and/or explosion. 3. Fuel vapors rising from the fairing and exiting the top of the fairing between the instrument panel and fuel tank, are blown by airflow into the riders face. The carcinogenic aspects of fuel inhalation are documented. Examination of the fuel pump assembly suggests that the high-pressure fuel quick disconnect reinforcement flange was inadequately designed for the fuel pump outlet pressures. The non-metallic (composite) pump housing combined with a composite high-pressure disconnect fitting is unsuited for the part. High pump pressure expands the composite high-pressure fitting causing it to readily load the fuel pump high-pressure quick disconnect flange. Over time, pressure cycling causes the quick disconnect reinforcement flange to crack allowing fuel to leak.
Fuel tank quick disconnect cracked spilling fuel while riding.
Tl* the contact owns a 2005 bmw r 1200 rt. While parked with the engine running, fuel began to spill onto the engine and onto the contact. The contact inspected the vehicle and noticed a fracture on the fuel flange near the fuel pump quick disconnect. The vehicle was not taken to the dealer for a diagnostic test. The vehicle was not repaired. The approximate failure mileage was 53,000.
Cracks on the high pressure side of fuel pump at the fitting. This will cause fuel to leak under operation with possible fire. Pump design is faulty and a recall should be intiated for this dangerous problem.
Cracks have developed in the fuel quick disconnect reinforcement flange on the fuel pump housing. This could lead to a fuel leak (and has in many cases) on to the exhaust pipe, ignition system components, and my left leg.
Multiple cracks in fuel pump housing at flange where fuel line connects. Odor and gas leakage.
Fuel pump flange cracked in at least four places that I can photograph. For how long this has been I cannot determine. Although it is not leaking fuel at this time several riders of this model have experienced the exact flange failure that resulted in fuel flowing out of the crack and onto the motorcycle and rider. Fuel on a person, in the air and on the vehicle is a chemical hazard and environmental hazard at the very least and fuel in the presence of an ignition source inches away is deadly. I believe it is a major safety issue and something should be done about it by the manufacturer. 8tt
Fuel was leaking from the flange around the female quick-disconnect fitting. Plastic flange is located on top of fuel tank. Replaced plastic fitting with metal one but leaks continued. Placed original fitting back and used a fuel-resistant sealing compound to stop leaks. Have not experienced any large leaks recently but am concerned this patch will start leaking again. It was a frightening experience to be riding and seeing gas splatter on your clothes - couldn't wait until I got home. The flange design is at fault because it prevents a solid connection of high pressure gasoline lines to the fuel tank.
Failure of the fuel pump housing high-pressure fuel quick disconnect reinforcement flange cracks under high pressure cycling and leaks, sending raw fuel down the left fairing in close proximity of the vehicles left exhaust pipe and ignition system components. The vehicles fairing effectively captures the fuel vapors creating a significant risk for fire. In addition, leaking fuel, streaming along the left fairing is exhausted on the riders left leg, creating significant risk for the rider even after dismounting the vehicle. Consequences of failure the combination of high fuel pressure and negligent design create substantial risk for riders of the impacted vehicles. There are multiple negative consequences of this failure, a few of which are outlined below: 1. Riders become fuel soaked as fuel leaks down the left fairing and then is forced by fairing airflow dynamics on to the riders left leg. 2. Fuel vapors, captured by the fairing and heated by the exhaust pipe become extremely volatile and could lead to a fire and/or explosion. 3. Fuel vapors rising from the fairing and exiting the top of the fairing between the instrument panel and fuel tank, are blown by airflow into the riders face. The carcinogenic aspects of fuel inhalation are documented. Preliminary analysis examination of the fuel pump assembly suggests that the high-pressure fuel quick disconnect reinforcement flange was inadequately designed for the fuel pump outlet pressures. Bmw's choice of a non-metallic (composite) pump housing combined with a composite high-pressure disconnect fitting was unwise and the failure mechanism is obvious. High pump pressure expands the composite high-pressure fitting causing it to readily load the fuel pump high-pressure quick disconnect flange. Over time, pressure cycling causes the quick disconnect reinforcement flange to crack allowing fuel to leak. Updated 10/20/11.
Tl*the contact owns a 2005 bmw r1200 rt. While the vehicle was stopped, the contact smelled gas. He noticed gasoline dripping from the tail pipe and his pants. The contact replaced the fuel check valve cover himself. The dealer stated that the fuel valve cover failing due to the defective plastic was a common issue. The current and failure mileages were 11,750.
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