24E020 – Accessory Top Case May Detach from Motorcycle – BMW R 1300 GS

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February 29, 2024 NHTSA CAMPAIGN NUMBER: 24E020000

Accessory Top Case May Detach from Motorcycle

A detached top case can become a hazard for road users and increase the risk of a crash.


NHTSA Campaign Number: 24E020

Manufacturer BMW of North America, LLC

Components EQUIPMENT

Potential Number of Units Affected 338



BMW of North America, LLC (BMW) is recalling certain BMW Motorcycle Dealer Accessory Top cases, designed for R 1300 GS motorcycles, and with part number 77 43 9 443 542. The dealer accessory top case locking flap may not function correctly, which can result in the top case detaching from the motorcycle.



Dealers will repair the locking mechanism of the top case and provide an insert for the rider’s manual regarding the locking mechanism, free of charge. Owners may contact BMW customer service at 1-800-525-7417.



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.





BMW is announcing a delivery stop for the Vario Top Case for the R 1300 GS for top cases produced up to 02/16/2024, part number 77 43 9 443 542. This safety recall involves the dealer accessory top case. The locking flap of the top case (fastening the top case to the luggage carrier of the motorcycle) may appear to be securely closed by the user. However, in this condition, the key can be removed. If this occurred, the top case would not be securely fastened to the motorcycle, could detach, and become a hazard for road users. No Vario Topcase for the R 1300 GS should be installed on the motorcycle; all stock needs to be returned. Any customer sold units also need to be returned, please reach out to those customers as needed.



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.



  • The image to the right shows the parts as depicted in ETK. Please see the table below regarding affected / blocked parts.
  • Affected parts are all remaining new, spare parts shipped and delivered to date only.
  • Please return all incorrect part(s) to your facing Regional Distribution Center (RDC).
  • Submit for return using a YR26 damage claim with order reason BM2. A valid BMW delivery and delivery item number must be entered, and ‘TEC617’ must appear in the text of your TEC claim.
  • Please directly request a FedEx Label when submitting ticket to have return shipping covered.
  • For assistance locating the delivery number, please open an IDS ticket with Dealer Services in the Claims section directed to Returns/Claims/Quality.



  • TEC617 is valid from February 14, 2024, through April 30, 2024.  The deadline for filing a claim under TEC617 is April 30, 2024.
  • All parts must be returned to your facing RDC no later than May 15, 2024.


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Chronology :

On November 21,2023, during a dealer demonstration ride of a R 1300 GS in a non-US market, a top case became detached from the luggage carrier and contacted the roadway. An engineering investigation was initiated, the part was returned for analysis, and the supplier was contacted.

Tests and analyses were planned of the design of the locking mechanism to understand the precision of the locking feature, and the mechanical resistance for key removal.

Between December 22nd and February 7th, four additional incidents occurred in non-US markets, specifically on December 22nd, January 24th and 27th, and February 7th in which customers complained that their top case had become detached from the luggage carrier and contacted the roadway. These parts were requested to be returned for analysis.

The first field part was received for analysis on January 23rd. Tests and analyses indicated that top cases that had fallen off could nevertheless, subsequently be securely fastened to the luggage rack if the locking mechanism was operated correctly. These tests also found that improper locking and subsequent removal of the key was facilitated by a very low mechanical resistance when turning the key (the mechanical resistance was not according to specifications). A review of the Rider’s Manual suggested that the description of the top case locking operation was not sufficiently clear.

By February 7th, all R 1300 GS motorcycles for the US market were still within the custody and control of BMW at the national motorcycle delivery center. A stop sale for the affected accessory top case was issued to dealers to ensure that no top cases could be retailed to customers. Therefore, it was not possible to equip a motorcycle with a potentially affected top case.

On February 8, 2024, BMW decided to conduct a voluntary safety recall for the accessory top case.

BMW has not received any reports, nor is BMW otherwise aware, of any accidents or injuries that relate to this issue.


1 Affected Product




4 Associated Documents

Recall Acknowledgement

RCAK-24E020-9592.pdf 645.331KB


Defect Notice 573 Report

RCLRPT-24E020-1372.PDF 215.32KB


Manufacturer Notices(to Dealers,etc) – Dealer Notice re AS1724 – Delivery Stop – Vario Top Case for R 1300 GS

RCMN-24E020-0486.pdf 84.063KB

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Remedy Instructions and TSB – Vario Top Case

RCRIT-24E020-8790.pdf 211.065KB

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Last update on 2024-05-08 / Affiliate links / Images from Amazon Product Advertising API

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