2002 BMW K1200RS Fuelpropulsion System Problems

TL* THE CONTACT OWNS A 2002 BMW K1200RS. WHILE DRIVING APPROXIMATELY 5 MPH, FUEL LEAKED FROM THE ENGINE COMPARTMENT WITHOUT WARNING. THE FAILURE RECURRED DAILY. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 04V028000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 28,000.

STARTED MY BMW K1200RS AND BACKED IT OUT OF THE GARAGE. NOTICED A SPRAY EMANATING FROM THE RIGHT SIDE OF THE ENGINE ABOVE THE VALVE COVE. SHUT THE BIKE DOWN AND CHECKED FOR THE LEAK. FOUND THAT THE PLASTIC FUEL LINE QUICK DISCONNECT COUPLING WAS CRACKED ALLOWING FUEL TO SPRAY OUT IN A FINE MIST. THIS COULD HAVE EASILY CAUGHT FIRE IF THE BIKE HAD BEEN HOT. CHECKED THE INTERNET AND FOUND THAT THIS FAILURE IS A COMMON PROBLEM ON BMW MOTORCYCLES AND IS NOT LIMITED TO MY MODEL OR YEAR. BMW HAS NOT SEEN FIT TO RECALL THE AFFECTED MOTORCYCLES EVEN THOUGH THEY ARE AWARE OF THIS PROBLEM AND HAVE REDESIGNED THE COUPLING. THE FUEL LINE IS PRESSURIZED AT 100PSI SO THE LIKELIHOOD OF A CATASTROPHIC EVENT IS HIGH. *TR

THIS IS A FOLLOW-UP TO MY FIRST REPORT OF THIS DATE. BMW APPARENTLY CONDUCTED A RECALL (04V-028) FOR LEAKS WITH THIS COUPLING, HOWEVER THE RECALL ADDRESSED LEAKS FROM THE QUICK DISCONNECT O-RING AND THE HOSE CLAMPS. IN THIS CASE THE BODY OF THE PLASTIC MALE END OF THE COUPLING INITIALLY CRACKS AND THEN SEPARATES ALLOWING FUEL UNDER 100 PSI TO FLOW DOWN THE ENGINE AND THEN TOWARDS THE REAR OF THE BIKE. THERE WAS ONE REPORT OF A FIRE AND AN INJURY FROM THE PREVIOUS RECALL. HERE WE HAVE A LEAK OCCURRING FROM THE SAME FITTING WITH THE SAME POTENTIAL. INITIALLY BMW REPLACED THIS FITTING WITH THE SAME ORIGINAL PART ONLY TO FIND THAT THE FITTING FAILED AGAIN. THIS PROBLEM CONTINUES TO PLAGUE BMW RIDERS AND NEEDS TO BE ADDRESSED. IT APPEARS THAT THE NTSB'S INITIAL INVESTIGATION WAS SUSPENDED WHEN THE MANUFACTURER AGREED TO A RECALL BACK IN THE 2004/5...