Fuel leak from crack in boss on Fuel Pump-Unit base plate
So my K1200S 2006 has got the dreaded crack in the plastic boss where the Quick Disconnect screws into the base plate of the Fuel Pump-unit. Of course the base plate is not available seperately and the complete unit includes the fuel pump R$,$$$.$$
Apparently this is problem that occures on a few models and the annotated photo attached, of the crack on my bike, could help identify a similar problem before the petrol squirts out under pressure from the pump - as it did on my bike. See also the forum thread from i-bmw.com:
I'm still in the process of considering my options, will post again on how it turns out.
I'll certainly follow this with interest Neville. Good luck!
Have to wait 4 weeks for the part . Planning to reinforce the boss by putting a Oetiker clamp on the boss before fitting the new one. Will be doing it for my GS as well as it has the same design.
Looks like the flanges made by Siemens VDO Germany are all going the same way. Please check your bikes and do not wait until you smell fuel or notice a leak. (especially when shopping for a used bike) In my opinion, this needs urgent attention because it is a serious safety issue that can cause injury or death.
I've noticed a fuel smell that progressively got worse, (on my 1200 GSA which I bought new in 2009) but never paid real attention to it. Some time later I noticed a couple of drops on the floor when on her side stand with a full tank. It didn’t take long to find the problem though - a BMW fuel coupling designed to fail sooner or later because of the taper design, causing permanent outward stress on the threaded plastic rim of the flange
So down to my local dealer that told me that this is a first and according to BMW, no such problem had ever been reported to BMW Motorad technical SA, but still offered me R 2000 goodwill discount on my R 7002.84 repair bill. (after 4 years and 30,000km - nice hey)
I think it's a serious design fault - not normal wear & tear and worth making a noise about even after your guarantee period. Related reports can go to Mr. Poulton - firstname.lastname@example.org
BMW fuel leaks - The taper design of the couplings causing cracks in the flanges
Here is only a few of many sites to check out:
I had the same on my 2008 GS. Repaired it (with a bit of help from my friend Neville!) about 2 months ago and no problems or leaks since. So far so good. This is a well documented problem extensively covered on several forums.
Check out media reports and my repair at
I bought a second hand BMW K1200R 2008 that had only 1500km in September 2011 from Lyndhurst BMW. When I got the motorcycle it was as new. Since I had the motorcycle in such a short space of time, the left hand side mirror blew off while I was riding then the right mirror blew off, then the fuel tank suddenly got minor cracks causing fuel to leak so badly at high pressure onto the hot exhaust manifold almost causing the bike to burn out while I was out riding, leaving me stranded in a bad spot next to the road. I consider these defective items to be serious and dangerous manufacturing defects. Surely bikes that have these defects should be recalled as this could easily have cost me my life if this happened while I was cornering. BMW refuses to acknowledge the defect and refuses to repair my fuel tank. I thought that buying a BMW would mean that I would get a reliable bike. This is really not the case. Familiar photo below;
Has anyone got a 'fix' for this issue?
Can it not be fixed by a plastic expert.
Touch wood - my repair as described in post above is still intact! Has lasted 9 months thus far.
I work in the plastic industry and by the looks of it,it looks like the plastic is a hdpe or similar. it should be possible to weld it. Unfortunately we dont have the appropriate welder to do the weld. You can try the guys at Gartech they do excellent work on plastic welding. Not sure if they would do such a thing but we have had things made by them which had to be plastic welded and the work is of good standard. Gartech 021-543 3388. Hope this helps.
Researching this issue I discovered an alarming number of cases where owners of R1200GS/RT/S bikes experienced this fuel leak, including a case where a bike burnt out. I am very surprised BMW have not had a recall. This has been fixed in later models with a metal supporting collar around this flange. It seems there are a few products available to 'fix' this as well as some Macgyvers. Alfie has just repaired one for my buddy by doing quite a clever mod to the design, now to put the assembly back and see if it worked.
It would be great if someone in the club could make a few of these as available from BeemerBoneYard, Johan, here's looking at you :-)
Recall. Will this be in SA as well?
The following models are affected:
2006 BMW HP2 ENDURO
2008-2009 BMW HP2 MEGAMOTO
2008-2010 BMW HP2 SPORT
2006-2008 BMW K 1200 GT
2006-2008 BMW K 1200 R
2007 BMW K 1200 R SPORT
2005-2008 BMW K 1200 S
2009-2011 BMW K 1300 GT
2009-2011 BMW K 1300 S
2012 BMW K 1600 GT
2012 BMW K 1600 GTL
2005-2011 BMW R 1200 GS
2006-2011 BMW R 1200 GS ADVENTURE
2007-2011 BMW R 1200 R
2005-2011 BMW R 1200 RT
2007 BMW R 1200 S
2005-2007 BMW R 1200 ST
2010-2011 BMW S 1000 RR
IOL also picked up this story:
"a BMW SA spokesman said he was unaware of the problem and that no cases had been reported."
Wheels24 would like to hear from you if you are experiencing this problem.
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