2008 BMW R 1200 RT

The bike is a 2008 BMW R1200RT. The throttle bodies for each cylinder has a plastic cam that is the point of attachment for the throttle cable. That plastic cam broke and completely detached from the bike. I was accelerating to merge into traffic on Interstate 64E at Corydon, IN. Once established in the right lane, the bike suddenly lost power and slowed rapidly while I was approached from the rear by a tractor trailer that had to apply brakes and continuously sounded his horn while abruptly maneuvering to the left lane to avoid me while I was attempting to assess what had just happened. This is a critical safety component and its failure has been documented countless number of times on various owner's group forums for this type of bike. One of which is linked here: https://www.bmwsporttouring.com/topic/91897-throttle-body-more-cracked-cable-camspulleys/ Another: https://forums.bmwmoa.org/showthread.php?76036-Broken-Throttle-Body-Pulleys-2009-R1200RT/page5 It is apparent the plastic that this throttle body cam is made from deteriorates rapidly causing a significant safety risk. There are aftermarket replacements that are made from aluminum, but they are very expensive. I am asking for a safety recall and that BMW be made to replace these parts with a metal or a material that is less prone to failure.

My forth vehicle with throttle body cams that are cracked and broken on both sides. No symptoms or warning lights of a problem that could have lead to a catastrophic failure, total engine propulsion failure, breakdown. My safety and others were in danger of injury or death. Dealer has confirmed and repaired all vehicles.

This is a two-cylinder engine with an independent throttle body for each cylinder. The throttle is actuated by a cable and pulley which rotate the throttle plate on a shaft. The pulley is attached to the shaft with molded plastic. Upon inspection during service, both plastic moldings (both cylinders) were discovered to be cracked and near failure. Failure of this part will cause that cylinder to go to idle power. If the vehicle is in motion, there will be a sudden loss of power, and high vibration until the throttle is closed. Until repair, the motorcycle will be inoperable. This has become a known defect with this series of motorcycles. I repaired mine using an aftermarket aluminum part created to address this problem. Parts cost was $458.

TL* THE CONTACT OWNS A 2008 BMW R 1200 RT MOTORCYCLE. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V141000 (WHEELS); HOWEVER, THE MANUFACTURER AND DEALER REFUSED TO HONOR THE REMEDY WHICH MENTIONED THE REPLACEMENT OF THE ALUMINUM REAR WHEEL FLANGE WITH A STEEL ONE. THE DEALER ONLY WANTED TO INSPECT THE VEHICLE. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

THE ABS AND REAR BRAKING SYSTEM FAILED. THIS WAS INDICATED BY AN INSTRUMENT PANEL RED WARNING LIGHT, "BRAKE FAILURE". AS A RESULT OF THIS FAILURE, THE REAR WHEEL BRAKE DID NOT OPERATE AS DESIGNED (INTEGRAL BRAKES) AND THE ABS SYSTEM WAS NON-FUNCTIONAL. THE SCANNED CODES STATE THAT THE POWER SUPPLY TO PUMP MOTOR IS FAULTY. *TR

FUEL GAUGE FAILED, WARNING LIGHT CONSTANTLY ON. BIKE COULD RUN OUT OF FUEL IN TRAFFIC WITH NO WARNING CAUSING DANGEROUS SITUATION. *TR

I AM WRITING IN RESPONSE TO YOUR INVESTIGATION CONCERNING BMW MOTORCYCLE FINAL DRIVE FAILURES AND WISH PROVIDE SUPPORTING INFORMATION. I HAVE A 2008 BMW R1200RT (VIN [XXX]) IN WHICH THE FINAL DRIVE DEVELOPED SIGNIFICANT ROUGHNESS IN THE REAR WHEEL ROTATION AND PRONOUNCED RUMBLING NOISE AT HIGHWAY SPEEDS AT ABOUT 22,000 MILES (EARLY 2011). I CONTINUED TO OPERATE THE MOTORCYCLE UNTIL 23, 400 MILES AT WHICH POINT I CONTACTED BMW USA AND MY LOCAL DEALER (AUGUST 2011). AS MY MOTORCYCLE WAS A FEW MONTHS OUT OF WARRANTY, NEITHER ORGANIZATION WAS PARTICULARLY HELPFUL. IT SHOULD BE NOTED THE FINAL DRIVE LUBRICATION WAS CHANGED AT 12,000 AND 18,000 MILES SERVICE INTERVALS. NO METAL SHAVINGS NOTED WHEN THE OIL WAS DRAINED. AT NO TIME WAS FINAL DRIVE OIL LEAKAGE EVIDENT. BEING A MECHANICALLY CAPABLE INDIVIDUAL, I ELECTED TO DIAGNOSE AND REPAIR THE FINAL DRIVE MYSELF. I DISMANTLED THE FINAL DRIVE AND INSPECTED THE CROWN WHEEL BEARING. I DISCOVERED SIGNIFICANT ROUGHNESS IN THE BEARINGS ROTATION. FURTHER, I CUT THE BEARING APART TO DETERMINE THE CAUSE OF THE ROUGHNESS. THE INSIDE OF THE BEARING STILL CONTAINED GREASE AND THERE WAS NO EVIDENCE OF FINAL DRIVE OIL LEAKAGE INTO THE BEARING ITSELF. AFTER CLEANING AWAY THE GREASE, I EXAMINED THE BEARINGS RACES AND BALL BEARINGS. I NOTED SIGNIFICANT PITTING AND METAL GALLING ON THE BALLS AND BEARING RACES. I REPLACED THE FAILED BEARING WITH A NEW BEARING AND REPLACED THE SEALS. TOTAL PART COST WAS APPROXIMATELY $200. I FABRICATED THE NECESSARY SPECIAL TOOLS TO PERFORM THE REPAIR. I RETAINED THE FAILED BEARING SHOULD YOU BE INTERESTED IN EXAMINING IT. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).*TR

CRACKED FUEL PUMP INLET BUSHING. *TT

FUEL CONTROL HOUSING CRACKED AND LEAKED FUEL ALL OVER THE PLACE INCLUDING MY LEG. WHILE UNDER PRESSURE. *TR