2003 R1150R Known Issues

[challey]

motorcityrider said:

Wow! I am a Ford Motor Engineer and if we would have a fuel line issue like that on our cars or trucks, there would probably have been a national recall to repair them. Why didn't BMW offer free repairs?

Excellent question! Denial? Arrogance? Hubris? Parsimony?
BMW did actually issue a service bulletin that called for inspection of the fuel line clamps but did not authorize replacement and more importantly, did not address the quick disconnect issue at all. When I brought my '03 in to the dealer for the inspection, I directed them to replace all of the OEM clamps with FI clamps. Though I had to pay for the parts, I did not have to pay for the installation labor.

BMW was lucky with this problem - I do not believe that anyone was injured or killed as a direct result of the fuel line issues. So not only were there no lawsuits, BMW also avoided what may have been a substantial cost of repair. This was likely the goal and no doubt made the BMW accountants happy.

What is unfortunate is that this attitude appears to have become the standard BMW modus operandi. For example, BMW bikes have experienced substantially higher FD bearing and input shaft/clutch hub failures than would be expected. Yet the company has not been sympathetic to warranty repairs for what appears to be a combination of design and manufacturing problems.

In my opinion, this attitude is very shortsighted and I am sure that it will cost BMW much more in the long run than they will save on repairs. There are many postive aspects of BMW products and when they work well both their bikes and cars are a joy to operate. Unfortunately, the reluctance of the factory to stand firmly behind their products translates - at least for me - to an even greater reluctance to again purchase anything made by BMW.

Charlie

[Oilhead]

The fuel line connection is a recall item and the instrument wire cluster is a sevice bulletin which my dealer both notified me and completed at no charge.

For the fuel line connection recall, they installed some new o-rings, o-clamps, hose clamps, and gaskets.

The the wiring bulletin, they checked the wiring harness routing and installed an edge protector.

The fuel line recall notice I got officially from BMW not too long after I got my '02.

The Instrument cluster SB, my dealer told me about it when I was down there for something else and he did it right then and there.

[jeepinbanditrider]

So just so we have one list here lol

These are the things that need to be nipped in the bud BEFORE they become issues:

Snip zipties on wiring harness going to insturmnt cluster

Pull tank and add insulation to wiring harness in certain places (Can't remember where right now.)

Replace QDs. Replace fuel lines on bikes more than a few years old.

Did I miss something??

The FD and trans problems don't seem like they can really be fixed you just have to deal with them when/if they fail.

Anything I miss??

[TicTac50]

Mine was built in feb 2001 and its never had any issues (21k on it to date)

Combustor777
You are absolutely correct about earlier years of R1150's
Mine was built in July 2001 and I only had 3 problems:
1. Hall sensor, partially my fault.
2.Clutch slave cylinder, 100% my fault.
3. Rear seal, "who knows" fault.
I switched to 2004 model with low millage (ABS) bike and I am already looking at the NEW STARTER.
The CHROME on the muffler looks much better on my old bike and the new one is made much cheaper.
On my 2001 bike I still have original QD's and the gas tank came off at least 5-6 times.
Now I am also looking at the new QD's for that 2004 bike.
I am slowly beginning to understand why so many people still keep those old airheads.
Today I was at the BMW shop picking up some bolts for the bike and was looking at the new K1300s and F800st.
What is that thing on the right side of the handle bar? It looks like a jar I return to the nurse at my yearly physical.
BMW bikes are beginning to look like a Japanese bikes, but that BMW emblem keeps going UP in price.
I am keeping an eye on my riding buddy's new Kawasaki Concourse 14.
$$$ 13 $$$ grand and 6 years unlimited millage warranty keeps me up all night.

[Speedo66]

Anybody know if the instrument zip-ties are a problem also on the Rockster with the different headlight/instruments, or only on the regular R1150R models?

[challey]

Pull tank and add insulation to wiring harness in certain places (Can't remember where right now.)

Two locations:
1) The wire harness is gathered into a loop under the tank and attached to the frame at this location by a wire tie. Add insulation to the top of the loop, which is really the only spot that rub the tank. May also be worthwhile to reposition the loop a bit lower to make it less likely to rub the tank.
2) At the left rear corner of the battery tray where the primary wire bends upward to connect to the postive terminal of the battery. The bend is right at the corner of the battery tray and that sharp corner can easily dig into the wire.

Charlie

[challey]

Oilhead wrote:

The fuel line connection is a recall item and the instrument wire cluster is a sevice bulletin which my dealer both notified me and completed at no charge.

For the fuel line connection recall, they installed some new o-rings, o-clamps, hose clamps, and gaskets.

The the wiring bulletin, they checked the wiring harness routing and installed an edge protector.

The fuel line recall notice I got officially from BMW not too long after I got my '02.

The Instrument cluster SB, my dealer told me about it when I was down there for something else and he did it right then and there.

Wow, my dealer did none of these things!

When I brought my bike in for the fuel line recall, they told me that it involved checking and possibly tightening the fuel line clamps - nothing else. I had to pay them to remove the old clamps and install new ones as well as for new o-rings.

As to Service Bulletins, it's obvious now (after my harness failure) that the wire harness routing was never checked either. It would have been nice if they at least mentioned to me that there was a SB on this. Perhaps BMW should consider letting owners know that there are Service Bulletins out there so that we can make sure the dealers are paying attention to them.

It sounds like your dealer is on the ball and doing their bit to keep BMW owners happy. I only wish that mine had been even half as vigilant - it's easy to see now why they closed up shop about 2 years ago.

Charlie

[baltm604]

Had both the zip tie issue and just had a quick disconnect fail.

If memory serves me, the recall for the fuel system had to do with the clamps, not the quick disconnects. BMW did move away from the plastic disconnects to stainless steel.

Smelled gas driving home on friday and found a broken mail disconnect when I got home. Tank has not been off the bike for 10k (8months) so I would say that the plastic disconnects can fail at anytime, whether you do your own wrenching or not.

The parts guy at Chicago BMW sold me just the SS male connectors, he said to keep the plastic females.

In regards to the wiring harnesses, had the turn signal cancel stop working, the horn, and the left heated grip. all due to over tightend zip ties. cut and replace, and only pull them tight enought to SLIGHTLY grab press the wires so they don't slid around.

Bill

[R1150Rclean]

Please give me more detail on the fuel line issue and what I need to do. Thanks.

order these:
http://www.beemerboneyard.com/cpcqkdiscon.html

Drain fuel tank.

Remove a black plastic panel covering the fuel line quick disconnects (just above right throttle body)

cut 4 clamps holding the fuel line to the quick disconnects (dremel cutoff wheel works good here), be ready to catch fuel

install new QDs and clamps. be careful not to break the plastic fuel injection rails trying to monkey the QDs off/on, this is an expensive mistake.

Cyclerob just did this on my bike, so he can correct anything I missed but that is basically it.

What year was your bike built? Mine was built in '01 and the fuel lines were showing signs of age/cracking so I replaced those as well. That will require removing the tank which is no big deal. If you decide you want to do that I have enough leftover fuel line and clamps I'll send you for free, just pay for shipping (its $25+S&H from the boneyard).

Thanks, just ordered them. I had one break when I disconnected it to remove the tank ('03 R1150R). But you do not need to drain the fuel from the tank, just use a clamp on the fuel line.

[by]

I'd add the cap #36317665843 for $9.43 to the rear wheel; my dealer told me that it was only added at the late models and protects from water/rust.

Best regards,
Michael

[kgb]

I had just got my 2003 R1150R when my fuel line broke. $168 tow later and I was back on the road. I thought this was just a fluke. Now I know. Unfortunately I have the same part replaced that broke. Thanks guys.