2005 BMW R1200 GS Problems

What owners report

Owners of this model year most often report fuel leaks from plastic fuel pump flanges and quick-disconnect fittings, followed by cracks in the rear wheel flange and rear final drive oil leaks or bearing failures. Fuel leak reports mostly fall between about 16,000 and 35,000 miles, while wheel flange cracks are most often reported between about 12,000 and 50,000 miles. Brake and ABS warning reports appear less often in the sample and cover a more varied set of symptoms.

1. 1
   Fuel system

   Fuel leaks at plastic fuel pump flange and fittings

   • 18 complaints (35%)
   • median 34,210 mi at 7.9 yrs old (17 state mileage)
   • filed 2007–2020

   Owners describe fuel spraying, dripping, or pooling from the fuel pump flange, a plastic quick-disconnect fitting on the fuel line, or a cracked pump housing. Some report fuel landing on the hot exhaust, and others notice a fuel smell before finding the leak. A complaint says the manufacturer selected a metal connector as a replacement, and another says the motorcycle was not covered by a recall despite the same failure. An owner paid for the repair out of pocket because the motorcycle was out of warranty. Most reported between about 16,000 and 35,000 miles, with a few at 50,000 miles or more; some leaks were noticed after the bike was parked.

   Recall 13V617000Recall 20V471000

   What to check: Ask whether the fuel pump flange recall work and any fuel pump replacement it describes were carried out, and ask for the records. Check for a fuel smell, fuel residue near the pump, or a cracked plastic fitting when the side covers are off.

   2 excerpts from owner complaints in NHTSA records

   “The fuel pump fitting cracked while I was riding on the highway. This resulted in fuel spraying on me and dripping onto the engine when I stopped. The fitting and the flange are both made of a plastic material. The threads are npt type and as the fitting is screwed into the fuel pump flange the fit gets tighter. This design will eventually result in cracking. This is what happened to the plastic fitting which I replaced with a metal one. …”

   NHTSA complaint #10521322, filed 2013-06, 25,000 miles

   “After filling up on fuel and driving home (less than five miles), I parked the motorcycle. Later in the day, I noticed fuel on the asphalt beneath the bike and leaking from the fuel pump, down onto the engine, left exhaust pipe and other parts of the frame. Further inspecting, I found fuel pooled atop the fuel pump housing. Mopping up the fuel, I identified a hairline crack in the upper plastic housing that holds the fuel pump, fuel pump electronics and fuel line connection. …”

   NHTSA complaint #10488899, filed 2012-12, 127,988 miles
2. 2
   Wheels

   Cracks in rear wheel flange at the mounting holes

   • 9 complaints (18%)
   • median 32,390 mi at 9.7 yrs old (9 state mileage, few)
   • filed 2010–2020

   Owners report cracks in the rear wheel flange, often around the wheel bolt holes or the brake disc holes. Many found the cracks while replacing a tire or during an inspection, and some describe cracks at several of the mounting holes at once. Some complaints describe an aluminum flange, and some say a replacement part has since been redesigned. An owner stopped riding until the flange was repaired. Mostly reported between about 12,000 and 50,000 miles, with a few at 60,000 miles or more.

   Recall 15V141000

   What to check: Ask whether the rear wheel flange has been inspected or replaced, and check the flange around the bolt holes when the rear wheel is off. A recall describes flange cracks linked to over-tightened mounting bolts, so ask whether any recall work is documented.

   2 excerpts from owner complaints in NHTSA records

   “After noticing a small amount of excessive movement in the rear wheel when riding through turns, I got home and inspected the area and found cracks in the aluminum rear wheel flange at the wheel mounting holes. After researching the issue, I discovered this is a recalled part under recall campaign 15v-141. The recall instructs replacing the aluminum flange with a new steel flange. …”

   NHTSA complaint #11322263, filed 2020-04, 12,078 miles

   “Upon inspection, I discovered 4 of the 5 wheel mounting holes in the aluminum rear wheel flange are cracked. I have read about many people having this issue with this model vehicle. I've stopped riding until it is fixed because it could break causing an accident which could lead to injury or death.”

   NHTSA complaint #11324091, filed 2020-05, 12,078 miles
3. 3
   Transmission and drivetrain

   Rear final drive oil leaks and bearing failures

   • 13 complaints (25%)
   • median 43,200 mi at 7.3 yrs old (12 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2007–2014

   Owners describe oil leaking from the rear final drive, worn or failing bearings, and a rear wheel that moves side to side or wobbles. Some report oil on the rear wheel, and an owner says the drive shaft was also damaged. According to complaints, the dealer replaced the final drive, bearings, or seals in some cases, including under warranty. Reported between about 5,000 and 68,000 miles, with several under 20,000 miles and some over 50,000.

   1 related service bulletin

   What to check: Ask whether the rear final drive oil level and seals have been checked, and look for oil on the rear wheel or brake disc. Ask for records of any final drive, bearing, or rear drive cover work.

   2 excerpts from owner complaints in NHTSA records

   “On my Bmw r1200gs, I noticed oil leaking from the final drive. It turns out that the seal was only an indication that the drive was failing. The dealer confirmed this and has replaced the final drive under warranty. There ar rumors of this being a common problem for r1200 series bmws. The old final drive is not available.”

   NHTSA complaint #10209020, filed 2007-11, 39,400 miles

   “Rear wheel moved side to side (bearing about to fail). Second r1200gs I owned with same safety failure, replaced and sold motorcycle at severe loss as two r1200gs rear drive failures on two low mileage r1200gs. Loss of thousands upon thousands of dollars.”

   NHTSA complaint #10447862, filed 2012-02, 5,300 miles
4. 4
   Brakes

   ABS warnings and reduced braking

   • 9 complaints (18%)
   • median 42,398 mi at 8.5 yrs old (9 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2006–2017

   Owners describe the ABS turning off with a warning light, leaving only residual braking. A complaint says the dealer reset the ABS computer, but the problem returned about a week later. Other complaints describe a near-total loss of braking on a slow turn and a suspected faulty front brake switch. Some owners also report rear brake pads wearing out much sooner than expected, and a complaint says the manufacturer considers this normal for these bikes. Reported between about 3,000 and 51,000 miles, with the lowest-mileage reports tied to ABS warnings and rear pad wear.

   Recall 06V164000Recall 06V134000

   What to check: Ask whether the ABS and brake warning lights stay off during a test ride, and whether the front ABS sensor cable routing was checked, since a recall describes routing problems after caliper work. Ask for brake and ABS service records, including any reset done by the dealer.

   2 excerpts from owner complaints in NHTSA records

   “I experienced a 100% no brakes situation coming into a slow speed 90 degree turn on a back road. Luckily I hadn't been going to fast and was able to down shift and scrub a little speed but forced with only engine braking and a very old asphalt road covered in gravel I had to lay it down to stop from going into a 60ft+ ravine. I've put 250-300k of street riding under my butt and this is the first time I've laid a bike down. …”

   NHTSA complaint #10717109, filed 2015-05, 51,010 miles

   “Rear brake pads wear out prematurely, typically in 6000 miles, as opposed to typical pad life which is ~18-24000 miles. No symptoms were noted previous to the brake pads wearing out. When rear brake pads wear out, there is loss of rear braking ability. This did not cause an accident for me, but could easily catch a rider by surprise and cause a crash as a result of loss of rear brake. …”

   NHTSA complaint #10202317, filed 2007-09, 6,000 miles

Buying note. Buyers considering this model year may want to check for a fuel smell or fuel residue near the fuel pump, look for oil around the rear wheel, and inspect the rear wheel flange for cracks around the bolt holes. Ask for records of recall and service work on those parts and on the ABS system.

Summary written with AI from a sample of 44 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.