2002 BMW K1200RS Fuel system Problems

“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. …”

“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. …”

“Male end of fuel quick disconnect broke, spraying fuel. When I called the dealer, they said that this was common, and that mine had a plastic male end, and that a replacement male end was available for twenty something dollars and was being used as original equipment on later model bikes.. For me this ended well. I noticed it as I was about to enter the garage. There are two quick disconnects and I plan on replacing both male ends with the new improved models. Mine also did not break off entirely, but cracked and sprayed a thin stream of fuel through hole in the body work. …”

“2002 Bmw K1200RS motorcycle fuel line quick disconnect coupling failed while in use causing fuel under high pressure to leak out onto hot engine & rider's right leg, risking fire, crash and serious injury or possible death. Owner at own expense and time replaced all four couplings and clamps, two male and two female. Old parts are available.”

“1;excessive fuel consumption - gage reading vs. Mileage driven. Heavy gasoline odor when stopped, severe gasoline leak. 2; mechanical failure of fuel line quick disconnect fitting on fuel return line - - cracked fitting. 3; carried out roadside repair. Removed faulty fitting and replaced with straight connector and clamps.”