Riding to work I noticed the smell of gas - I parked the bike and noticed a steady of gasoline dripping out from under the left front fairing (plastic gas tank and fuel pump are behind the left fairing). I removed the various fairing parts and noticed pooling of gasoline in the reservoir on top of the fuel pump flange. I dried out the top of the flange and turned the key back on to engage the fuel pump and discovered several areas where the gasoline was spraying from the high pressure, 90 degree gas line below the base of the male connector and only on the shroud of the female connection - both the 90 degree male side and the connecting line were wholly intact and seated fully into the connection. I disconnected the line and removed the male connector and discovered multiple cracks around the surface of the female receptor that passed into the threaded area of the flange (which allowed gas to spray out when it was under pressure). The bike is back home and inoperable now - the bike as mentioned above, is a 2007 bmw r1200rt with just over 21,000 miles on it.
2007 BMW R1200 RT fuel system complaints
Page 2 of 2: complaints 11 to 37 of 37, newest first, as owners wrote them.
Riding at about 50 MPH, my passenger asked to pull over, "we are leaking something". I pulled over and inspected the bike, we were leaking fuel from the fuel pump. Fuel was leaking down the faring & on to my left pant leg and boot. I immediately took the bike in to the bmw motorcycle shop for inspection & repair.
Sirs, I am the original purchaser/owner of a bmw r1200rt motorcycle, VIN# [xxx]. I have had to replace the fuel gauge sensor (part # 16147675547 - sensor and # 16117677883 - gasket) three times already. Now it has failed again. This is the 4th time it has needed to be replaced in 6 years. I contacted my dealer (bmw motorcycles of countryside il) and spoke with service manager [xxx]. [xxx] informed that my last fuel sensor replacement was 27 months ago and therefore it will not be covered under warranty (24 month), despite it having failed and been replaced multiple times and despite the fact that the motorcycle has less than 14,000 miles on it. He then estimated it would cost me $350 to replace the sensor. If this was the first time I had to replace the sensor, I would unhappily pay the $350 and attribute it to the motorcycle being 7 years old as the mileage is negligible. But this is not the case. This part has repeatedly failed. [xxx] acknowledged that this is a widespread and recurrent problem. My own research indicates that multitudes of bmw r1200 model motorcycle owners have also been experiencing multiple and repetitive fuel sensor failures for many years. This issue is documented under the federal safety agency id # 10033130 and bmw service bulletin no. Sib-16-02-09. This r1200rt is the most expensive motorcycle I have ever purchased. I find it unconscionable that bmw expects me to pay the full replacement cost of a part that has required multiple replacements over the course of 14,000 miles, a part that obviously is the subject of an inherent design/manufacturing flaw. Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).
Yet another fuel level sensor strip [fuel gauge] failure. This is number 6. Now no longer covered and cost $350 to replace at the dealer - 250 miles from my home. I think this is a safety issue because here in the western us where it's possible to travel over 100 miles without seeing another smiling face, running out of fuel is a serious threat to your safety.
While I was backing my motorcycle into the garage I smelled a strong odor of gasoline. As I dismounted I noticed a liquid dripping on the ground next to the left exhaust pipe which turned out to be gasoline. I removed the body panels to investigate and found a puddle of fuel on top of the fuel pump assembly. Further investigation revealed fuel leaking from the boss that holds the female fuel line quick disconnect. I removed the female quick disconnect and reapplied fuel resistant sealant to it and let it sit overnight, thinking that was the problem. I reconnected the fuel line and pressurized the system. It still leaked only worse now. When I attempted to tighten the fitting a bit gas actually squirted out of the joint between the fitting and the boss. This caused me to investigate further and discover that the were 4 to 5 small cracks in the boss on the fuel pump assembly where the fuel pressure line female quick disconnect screws in. Being that the fuel pump assembly sits about the left exhaust pipe where it comes out of the cylinder head a gas leak from this area is a fire hazard. I shudder to think of what would have happened if one of those drops of gasoline had dripped on my exhaust pipe.
Fuel pump assembly started leaking and fuel started running down the left side of the motorcycle. The pump assembly was leaking badly and the bike could not be operated. Ref:pe12-036.
My motorcycle ran out of fuel while indicating 1/2 full on the fuel gauge. I was on a busy us highway and had to coast to the soft shoulder of the road, where the bike almost tipped over into the traffic lane when the kickstand sunk into the soft ground. Fortunately another biker had a hose and we were able to siphon enough fuel using a coke can for me to make it to a gas station. Since that time the gauge has always indicated no less than 1/2 tank, even when empty. This is a safety hazard in particular for someone on 2 wheels. A sudden loss of power at lower speeds could have resulted in the bike tipping over in the roadway, causing injury to me & endangering me and others. Since that time I have learned that many other bmw riders are having the same problem, and that bmw denies the existence of this problem.
Park on side stand, engine running in neutral, gas started leaking from the left side fairing : one drop every 3 seconds.
During routine systems check, discovered that the top of the fuel pump housing (specifically the ridge at the base of fuel line disconnect) had developed numerous cracks and no longer appears safe, allowing fuel to leak.
Cracked boss/molded fitting on fuel pump/sending unit on fuel tank, leaking fuel.
Fuel control module stopped working,which disables the bike and it will not run. Removed the module and found the pc board burned and shorted, due to fuel seepage coming from fuel pump and arcing under the board. The fuel is coming from a fuel nipple fitting located adjacent to the module. Inspected the fuel pump fitting and found 4 cracks radiating from the threaded section into the body of the fuel pump. No repair available from bmw and the only alternative is to replace the fuel pump assembly which lists for almost 500 dollars and still has the flawed nipple design. Cleaned the area and made a repair using a 2 part epoxy resin. It has been fairly good but is beginning to deteriorate and begin seeping. The new fuel pumps have been modified with a thicker threaded section and a support collar. You can smell fuel at times and this system is pressurized creating a very real fire danger.!!
Cracks exist on fuel pump flange identical to those reported in pe12-036. There are numerous cracks around the fuel pump flange that could lead to failure/fuel leak.
While performing maintanance on my motorcycle,I found deep cracks in the fuel pump boss where the high pressure fuel line attaches. If the cracks become any deeper,fuel will leak and spray onto my engine and exhaust.
I was riding at night, suddenly saw smog coming from the front of motorcycle and gas odor and felt a wet left leg and shoe, pull aside and park noticing about a 1/4 gallon of fuel spill, after few minutes my left hand, shoulder and neck just below my helmet start to feel irritation on skin a burn feeling, after removing fairings found out a cracked fuel pump and leaking quick disconnect fitting at high pressure. In case of fire the poor fuel pump design put myself in a real hazardous situation.
Traveling on I-44 east of joplin mo. Significant odor of gasoline. Found a safe place to pull off highway and saw fuel dripping from under the left fairing panel. Removed the panel to find puddles of gas in the fairing recess and the fuel pump recess. Wiped it all up and turned on the key, which started the pump and a strong stream of fuel was pumped out from a serious crack in the fuel pump plate at the fuel line fitting. The motorcycle was unsafe to ride so I called for a trailer, trailered the bike to kansas city, mo and engle motors. The entire fuel pump assy had to be replaced at a cost of $621.52. There is no question I was very lucky the motorcycle didn't catch fire while I was riding it. I called and filed a complaint to bmw with no response. I have receipts to prove the failure and witnesses. Bmw needs to own this failure and recall all these machines to insure no one dies as a result of this. Calling this a fire hazard is understating the problem.
As I was doing routine maintenance, I noticed several small cracks on the "flange" where the quick disconnect exits the tank. I used a ring clamp to close the cracks. I believe this to be potentially very dangerous, since leaking gasoline could easily run down the outside of the tank and end up on hot engine/exhaust parts, causing a fire...
Tl* the contact owns 2007 bmw r1200rt motorcycle. The contact stated there was a crack in the fuel pump causing the fuel to leak. When routine service was done on the vehicle when the mechanic noticed the fuel leak. The mechanic stated that the fuel pump needed to be replaced. The manufacturer was not notified. The failure mileage was 98,077.
Vehicle ran out of fuel, while fuel indicator showed there was 1/4 tank left.
Repeated fuel pump failure from electronic (failure) due to the design that allows water to collect in a "well" where the pump's module is located. Third fuel pump in 3 years. The motorcycle shuts down suddenly, last time being in heavy city traffic with no shoulder. I had no escape route and the vehicle behind me nearly rear ended me, and required emergency braking to avoid collision and striking me.
Fuel gauge read 3/4 tank of gas and vehicle fuel tank was empty - had to walk home.
The plastic electric fuel pump has developed cracks around a high pressure output fitting that carries fuel to the fuel injection system. It is possible to smell gas fumes around this area of the vehicle. There are stains on the pump that confirms the fuel leak. This leaky fitting is located within two inches of various electrical connectors used for engine management functions (fuel level, etc). All it takes is for a spark from these connectors to ignite gas fumes from the leaky connector to cause a vehicle fire. This is a fire hazard that could endanger the life of the driver as well as the vehicle itself. Most motorcycles are stored in closed garages and there is the potential of a fire, property loss or loss of life or an explosion if a motorcycle with this defect is parked nearby a gas water heater.
A single crack has appeared in the plastic, threaded boss on the fuel pump assembly into which a quick-disconnect fuel supply component screws. Investigated owing to fuel smell pervasive when the motorcycle is garaged. Possibly some fuel vapors leak from said crack.
Noticed fuel residual on left side fairing of motorcycle. Removed fairing to find source of fuel leak. Found the outlet flange on the fuel pump high pressure outlet leaking fuel, & cracked in four different locations. I'm not sure when these cracks occurred and fuel started leaking. I discovered the leak only when it got bad enough to blow back on the motorcycle fairing. I was at home when I discovered this leak after a ride, so I entered 0 MPH on this incident information. I ride the bike between 5 MPH, to 80 MPH depending on where I'm at. (interstate, highway, city, ect.).
Riding down hwy 87a in az,,felt my left leg getting wet and smelled fuel,,pulled over on the side of the road and noticed fuel dripping on the ground,,trailered bike to my home,,remove the body panels and found the top fitting of the fuel pump cracked and spraying fuel,,,,I think im dam luck it did not ignite on the hot exhaust ,,,
Fuel tank flange cracked where gas line connects. I have another bmw that did the exact same thing. This has happened to many bikes and it is a very dangerous fire hazard to the rider.
The fuel sensor on my 2007 bmw r 1200 rt failed while I was riding it causing the fuel gauge to read empty. This could cause a person to run out of gas at anytime. This has occurred to numerous other bmw r bikes and is a problem bmw is well aware of.
When I parked after a ride I smelled fuel and had some dripping on the floor from the lh fairing. Pulled the cowling and found the top of the fuel pump housing full of fuel. Cleaned it up and put power to it and found the flange, below the quick disconnect fitting, cracked in 3 places. This area has never been touched since built. My shop and forum searches indicate this is a relatively common problem. The potential for fire was high.
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