Stupid Telelever System!!

[leoquattro]

I must say I never really liked the telelever front suspension system of our bike: I was accustomed for instance to feel the strength of my braking also through the “dipping” of the front fork. The experience I got, convinced me even more.

Here is what happened: after refuelling my bike I got it down its center stand.
When the front wheel touched the ground, the whole front part of the bike went also down, with the fork at a strange angle.

It looked like I was on a chopper!!!!

The bolt of the telelever disengaged from its seat and the front wheel was remaining attached to the rest of the bike only through the top fork attachments and the various cables and wires.

After recovering from the scare (thinking what could have happened if this accident occurred while driving, probably I wouldn’t be here writing this mail!!) and after unsuccessfully trying to reattach the bolt into its seat, I called the BMW Emergency Service and had my bike brought to the BMW shop (being in Rome it is the Main BMW center in my country).

Everyone there was horrified by the accident and all mechanics said it never happened before (apart as a consequence of serious accidents). The threads of the fork bridge were ripped off in their last two/three rings, so what probably happened is that the silly bolt went loose and eventually ripped off the final threads because of the strain.

Of course I complained very strongly with BMW Italy but the only satisfaction I got was free spare parts (it was not the point!!!), since they claimed that the bolt is assembled originally using a special glue and something like that happening after 25,000 km could only be due to a hard hit. I had no such hard hit, but since I bought the bike second hand two years ago I couldn’t swear for the previous owner. As a matter of fact I called him and he guaranteed me of no problem whatsoever, but who knows!

In any case, what I complained about with BMW is that the brilliant German engineers who designed the front suspension system, relied too much on “special glue” to keep two such important and stressed parts together. Why do not use a locking nut or a simple locking pin? It would have been invisible anyway being below the fork bridge. It is a matter of serious risk if not human life! The BMW engineers can still make use of their beloved “special glue” to keep their hats on their heads during the windy German winters!

The stubborn BMW experts eventually admitted I was right and that they will pass the suggestion to Munich designers (!?!).

Has anything like that ever happened before to your expert knowledge?

Ciao to all
Lq

[cruiser]

Lq, I'm sorry to read about the worrying damage to your front telelever but so glad that the bolt didn't come adrift whilst you were riding.

Even more of a worry is that, apparently, you're not the first to experience this potentially fatal occurrence... http://r1150r.org/board/viewtopic.php?t ... =telelever

[boxermania]

Buon sera Signore

Never seen a failure like yours before....let's just say that you were blessed not to be ridding the bike at the time.

Nice to have you with us....and like John Wayne used to say when the horse thrw you off....just dust yourself and get on that saddle again.....

Best of luck......do you have the failed part, or can you get some pictures?

[Dr. Strangelove]

Actually, someone reported a similar failure, while riding at 80mph, a few months back.

Said he lost that bolt. he managed to stop and live.

How can we check that bolt? I looked at mine and it "appears" ok, but...


John

[leoquattro]

Thank you all.
Thanks Cruiser the previous post is even scarier (reminded me of the novel Airframe - I think that was the title- by Michael Chrichton where the autopilot gets looped and it's a disaster!).
Now that you showed me that such accident is not a rare event, I'll write again to BMW.
Yes Boxermania I am riding again but when my mind goes to that bolt I feel a cold ripple in my spine.
Unluckily I was so angry I didn't think of getting some pictures of the damage.
John, the mechanics there told me that the bolt is assembled with the famous glue and a torque wrench properly set, so I don't think one could tighten it once in a while. Only thing you can do is to check it raising a bit the rubber cover around it.

Ciao
Lq

[sweatmark]

Noted BMW Telelever recalls:

http://ohio.adtaker.com/recalls/info.as ... BMW+R1200C

Heard about this on the Chromeheads board when we owned an R1200C Cruiser. We've noted here on the Roadster board (similarly on the Pelican R1100S board) that the Rockster blue finished parts have can exhibit surface corrosion, eg. fork tubes.

http://ohio.adtaker.com/recalls/info.as ... W+R1100+RS

See notes for Campaign #94V233002.

And from NHTSA website:

NHTSA Campaign ID number : 94V233002
Make / Models : Model/Build Years:
BMW / R1100 RS 1994-1995
Manufacturer : BAYERISCHE MOTOREN WERKE
NHTSA CAMPAIGN ID Number : 94V233002 Mfr's Report Date : NOV 18, 1994
Component: SUSPENSION:FRONT
Potential Number Of Units Affected : 2000
Summary:
THE NUT THAT SECURES THE FRONT FORK LOWER BRIDGE BALL JOINT TO THE TELELEVER SUSPENSION ARM CAN LOOSEN.
Consequence:
IF THE BALL JOINT NUT LOOSENS, STABILITY OF THE MOTORCYCLE CAN BE IMPAIRED. THIS CONDITION CAN RESULT IN LOSS OF CONTROLAND AN ACCIDENT.
Remedy:
DEALERS WILL REPLACE THE BALL JOINT NUT AND SECURE IT WITH LOCTITE.
Notes:
SYSTEM: SUSPENSION: MOTORCYCLE FRONT. VEHICLE DESCRIPTION: MOTORCYCLES. NOTE: IF THE VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME, OR THE REMEDY DOES NOT CORRECT THE DEFECT, PLEASE CONTACT BMW AT 1-800-831-1117. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.


Sounds similar to what's described within this message thread. Scary.

[DJ Downunder]

I'd be angry also..But I also think you've just had bad luck Re this because it's such a rare thing to have happen.

I love the design of our front end..and it's one of the things that makes our bikes so special.

DJ

[Acpantera]

Say what you want about the telelever front end, but as with any vehicle, nearly all the nuts and bolts that secure suspension,brake,and steering components are very important safety items and must be inspected regularly. As for my feelings for the telelever,I love it! it has saved my life after hitting a large crevis in the road that badly bent the front wheel, but I never lost control. BMW's design was intended to hit a 4" curb at a 90 degree angle at 60mph and still maintain control.......IT WORKS. I have been riding alot of years and I know that a regular road going telescopic fork would have failed and compromised vehicle stability.

[CycleRob]

Yikes!!

That failure is scary. Obviously the assembly line omitted or shorted the red loctite that should have been applied.

Here's where one of the TeleLever failures occurred. Part 13 unthreaded from part 11, then a bad accident happened.

Lucky that leoquattro's came apart taking it off the centerstand.

I think the TeleLever is the best M/C suspension system made. No braking dive. One replaceable, adjustable, external (aftermarket) shock. Superior stability from stellar system parts rigidity. Zero suspension stickshun. Zero maintenance.

Mine gets checked out tomorrow, drilled and safety wired at both ends (parts 11, 13 & 15). I'm not betting my life on 2 in 10,000 chance of bad work from an assembly line worker.


.

[towerworker]

I saw this on the same site mentioned by Sweatmark......


2004 BMW R1150 R - Campaign #04V235000
Summary: SUSPENSION
Defect:
ON CERTAIN MOTORCYCLES, THE FRONT SPRING STRUT UPPER STUD BOLT WELD CAN FAIL. THIS COULD CAUSE THE BOLT TO BREAK.
Consequence:
IF THIS HAPPENS, THE RIDER MAY NOT BE ABLE TO CONTROL THE MOTORCYCLE, WHICH COULD CAUSE A CRASH WITHOUT WARNING.
Corrective action:
DEALERS WILL REPLACE THE FRONT SPRING STRUT. THE RECALL BEGAN DURING JUNE 2004. OWNERS SHOULD CONTACT BMW AT 1-800-331-1117.


What they refer to as the "front spring strut"........are they talking about the telelever?

Apparently this began in 2004 and all affected machines are by now corrected (hopefully) ........that being said I plan to make the phone call and have my vin# checked.

Wayne

[leoquattro]

Yes DJ, it was bad luck but also very good luck that it happened while standing still.

I continue to like the bike which I consider much superior to many others: only thing is why BMW doesn't apply some common sense and simply does what Cyclerob is suggesting, drill two holes and put two safety pins or wire.

Ciao
Lq

[awagnon]

Mine gets checked out tomorrow, drilled and safety wired at both ends (parts 11, 13 & 15). I'm not betting my life on 2 in 10,000 chance of bad work from an assembly line worker.

Hey, CycleRob. How about some photos after you get finished? I'd like to do the same.

[CycleRob]

Well, the deed is done! Everything was tight, but I drilled and wired it up with thick .043" wire anyway. Drilling access possible at full steering lock, both ways. I thought the drilling would be thru very hard materials, but it was surprisingly too too easy. Aluminum fork boss had to be drilled for a minimal sized mounting point hole. Wire holes were chamfered to reduce the possibility of wire cutting on loosening. Lastly, the plastic nut cover needed an internal relief channel so the wire did not bulge it out.

Peace of mind @70MPH over big bumps now back to max.



EDIT: To replace inadequate pic with a fully detailed one.
.

[DJ Downunder]

Great job CycleRob...and great pictures...Thanks.

DJ

[awagnon]

That was fast! Good job and clear pictures. Now if I can find some safety wire.

[leoquattro]

Simple and effective, that's real engineering, thanks Cyclerob
Lq

[Beemeridian]

22

[Boxer04]

CycleRob,

Thankyou for the clear photos. The job you have done is as neat and effective as anything you would expect to see from a quality race car preparation shop or a licenced air frame engineering establishment.

Well done!

[Dr. Strangelove]

CR, thanks,

few questions, please?

The shaft of 13 is hollow? so you only had to drill to the center and then loop up and twist?

What size bit, type bit did you use?

A dremel or a "grown up drill" ?

Did you check the tightness of everything before you drilled?

The bottom nut...how is that secured by the wire, we can see the twisted end, but it looks like it is flapping in the breeze?

On the bottom nut--did you just go in on the flats, by the corner, 90 and 90, met the holes and ran the wired through the bend?


Thanks.

And there was a similar report from a member across the Pond that described this falling apart at 80 mph--maybe 8-10 months ago???


John, "ass-u-ming" that setup is secure in New Orleans

[Robert_winter_1000]

Noted BMW Telelever recalls:

http://ohio.adtaker.com/recalls/info.as ... BMW+R1200C

Heard about this on the Chromeheads board when we owned an R1200C Cruiser. We've noted here on the Roadster board (similarly on the Pelican R1100S board) that the Rockster blue finished parts have can exhibit surface corrosion, eg. fork tubes.

http://ohio.adtaker.com/recalls/info.as ... W+R1100+RS

See notes for Campaign #94V233002.

And from NHTSA website:

NHTSA Campaign ID number : 94V233002
Make / Models : Model/Build Years:
BMW / R1100 RS 1994-1995
Manufacturer : BAYERISCHE MOTOREN WERKE
NHTSA CAMPAIGN ID Number : 94V233002 Mfr's Report Date : NOV 18, 1994
Component: SUSPENSION:FRONT
Potential Number Of Units Affected : 2000
Summary:
THE NUT THAT SECURES THE FRONT FORK LOWER BRIDGE BALL JOINT TO THE TELELEVER SUSPENSION ARM CAN LOOSEN.
Consequence:
IF THE BALL JOINT NUT LOOSENS, STABILITY OF THE MOTORCYCLE CAN BE IMPAIRED. THIS CONDITION CAN RESULT IN LOSS OF CONTROLAND AN ACCIDENT.
Remedy:
DEALERS WILL REPLACE THE BALL JOINT NUT AND SECURE IT WITH LOCTITE.
Notes:
SYSTEM: SUSPENSION: MOTORCYCLE FRONT. VEHICLE DESCRIPTION: MOTORCYCLES. NOTE: IF THE VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME, OR THE REMEDY DOES NOT CORRECT THE DEFECT, PLEASE CONTACT BMW AT 1-800-831-1117. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.


Sounds similar to what's described within this message thread. Scary.

leoquattro,
Is your bike from 2004?
regards
Robert