Gearbox Input Shaft – 2019-2023 BMW R1250GS / GS Adventure / RTP

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January 18, 2023 NHTSA CAMPAIGN NUMBER: 23V011000

Gearbox Input Shaft May Break

A damaged gearbox input shaft or a blocked rear wheel can increase the risk of a crash.

 

NHTSA Campaign Number: 23V011

Manufacturer BMW of North America, LLC

Components POWER TRAIN

Potential Number of Units Affected 18,489

 

Summary

BMW of North America, LLC (BMW) is recalling certain 2019-2023 R1250GS, R1250GS Adventure, and R1250RTP motorcycles. In certain engine operating and riding conditions, the gearbox input shaft may become damaged or break, possibly resulting in a blocked rear wheel.

 

Remedy

Dealers will update the engine control unit software, free of charge. Owner notification letters were mailed February 22, 2023. Owners may contact BMW customer service at 1-800-525-7417.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your BMW Motorcycle has a Recall

 


SIB 23 01 23
2023-01-18

RECALL: REPROGRAM R 1250 GS, GS ADVENTURE, AND RTP MODELS

 

MODEL

Model Model Description Production Date
K50 R 1250 GS 8/27/2018 – 12/14/2022
K51 R 1250 GS Adventure 9/18/2018 – 12/14/2022
K52 (RTP) R 1250 RTP 7/11/2018 – 12/02/2022

The affected vehicles have been marked with campaign number 0000232600 in AIR.

In order to determine if a specific vehicle is affected by this campaign it will be necessary to verify the vehicle VIN in AIR (Aftersales Information Research). Based on the response of the system, either proceed with the repair or take no further action. Please note, open campaigns or vehicle stops may not appear in DCS Warranty Vehicle Inquiry or sales systems until 24-72 hours after they are announced, therefore AIR is always the recommended method for determining open campaigns and vehicle stops.

 

NHTSA STATEMENT

Please be reminded that it is a violation of federal law (The Safety Act) for you to sell, lease or deliver any new motorcycle covered by this notification until the recall repair has been performed. This means that dealers may not legally deliver new motorcycles to consumers until they are fixed or use/sell replacement equipment/parts subject to this recall. Note also that substantial civil penalties apply to violations of the Safety Act. Also, you should not sell, lease or deliver any used motorcycles subject to a safety recall until the repair is completed. Please follow any special instructions that we provide to you for the return or disposition of recall parts.

 

SITUATION

After close inspection it has been found that in rare cases that riding maneuvers with an abrupt RPM difference between the engine and final drive can result in an overload of the transmission input shaft. As a result the input shaft can break, which can lead to critical riding conditions.

This fault pattern can only occur in the above listed R 1250 models because the software application of the engine control permits significantly higher rev level differences than in the R 1200 models.

 

PROCEDURE

The engine control unit must be updated according to the model-specific repair instructions “61 00 510 – Programming vehicle control units”. The corresponding software (I level K001-22-11-501 or newer) is available at dealer level with ISTA version 4.39.2x.

For vehicles not yet delivered the software update must be completed prior to retail to the customer.

For vehicles already delivered to customers, the Recall must be carried out during the next workshop visit.

Customer letters have been sent to customers with retailed effected motorcycles to arrange a date and time to have the dealer perform the required software update for this Recall.

 

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BMW R1250GS / GS Adventure / RTP
Gearbox Input Shaft
Part 573 Chronology
January 18, 2023

In October 2020, BMW became aware of a 2019 BMW R1250 GS in Italy in which a customer complained about a broken gearbox input shaft and a blocked rear wheel.  Two additional similar complaints, in Italy and the Netherlands, in October and November 2020, involving 2019 BMW R1250GS models, were received.  An engineering investigation was initiated.

A parts return program was implemented, and the gearbox input shaft supplier was contacted.  Although it was noticed that the three customer complaint motorcycles were all produced in June 2019, a review of the supplier production process did not result in any finding.  Lab analyses involving material property evaluations, x-ray, scanning electron microscope, and surface treatment examinations did not result in any findings.  Initial analyses could not determine a root cause or systematic production anomaly.

In July 2021, a complaint involving a 2019 BMW R1250 GS Adventure in France, about a broken gearbox input shaft (but without a blocked rear wheel), was received.  Further analyses were conducted, including a continuation of the parts return program, and additional supplier production reviews and audits.  Various FMEAs were performed.  Additionally, bench and road tests were conducted, including potential customer misuse riding scenarios.  Further lab tests were performed involving force/torque applications, load change pulsations, x-ray, and dynamometer runs.  The root cause could still not be identified, and the market continued to be monitored.

In June 2022, BMW became aware of an incident involving a 2019 BMW R1250 GS in the United Kingdom that resulted in a crash with injury.  BMW intensified its investigation and analysis process, and in  August 2022, BMW became aware of an incident involving a 2019 R1250 GS in the Czech Republic of a crash without injury.  The analysis activities continued, including a review and comparison of engine, gearbox, and drivetrain design and operating parameters between the R1250 models and the prior generation R1200 models.

The engineering investigation concluded that in certain engine operating and riding conditions, an overload of the gearbox input shaft could occur, and result in damage to, or breakage of, the gearbox input shaft, and possibly result in a blocked rear wheel.

On January 10, 2023, BMW decided to conduct a voluntary safety recall.

 


15 Affected Products

Vehicles

MAKE MODEL YEAR
BMW R 1250 GS 2019-2023
BMW R 1250 GS ADVENTURE 2019-2023
BMW R 1250 RT 2019-2023

 


12 Associated Documents

Remedy Instructions and TSB

RCRIT-23V011-2024.pdf 127.828KB

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Manufacturer Notices(to Dealers,etc) – Delivery Stop

RCMN-23V011-4991.pdf 89.487KB

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Miscellaneous Document – Chronology

RMISC-23V011-6214.pdf 29.869KB

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Defect Notice 573 Report

RCLRPT-23V011-3383.PDF 215.236KB

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Recall Acknowledgement

RCAK-23V011-6351.pdf 645.221KB

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Manufacturer Notices(to Dealers,etc) – Update to Stop Sale STOP230005 Recall: Reprogram R 1250 GS (K50), R 1250 GS Adventure (K51) and R 1250 RTP (K52) models has been published and replaces Delivery Stop STOP230005

RCMN-23V011-5187.pdf 28.036KB

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Recall 573 Report – 2/16/23

RCLRPT-23V011-8434.PDF 215.234KB

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Recall 573 Report – 2/16/23

RCLRPT-23V011-2198.PDF 215.234KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V011-0283.pdf 712.97KB

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Recall Quarterly Report #1, 2023-1

RCLQRT-23V011-2742.PDF 211.135KB

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Recall Quarterly Report #2, 2023-2

RCLQRT-23V011-7720.PDF 211.239KB

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Recall Quarterly Report #3, 2023-3

RCLQRT-23V011-8421.PDF 211.462KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V011&docType=RCL

 


 

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