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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
Summary
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.
Remedy
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.
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.
TEC617 VARIO TOPCASE
RECALL 24E-020 HAS BEEN ISSUED FOR THE VARIO TOP CASE FOR R 1300 GS
OVERVIEW
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.
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.
RETURN DETAILS
- 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.
MORE DETAILS
- 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
Equipment
| BRAND | PART NO. | PRODUCTION DATES |
| BMW | ACC. TOP CASE R 1300 GS | |
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
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Remedy Instructions and TSB – Vario Top Case
RCRIT-24E020-8790.pdf 211.065KB
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Latest Recalls Documents
For the Latest and Most recent Recall Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24E020&docType=RCL
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SEOCONTENT-START
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24E-020
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
BMW of North America, LLC FEB 29, 2024 NHTSA Recall No. : 24E-020 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : BMW of North America, LLC Address : P.O. Box 1227
Westwood NJ 07675-1227
Company phone : 18005257417
Population :
Number of potentially involved : 338 Estimated percentage with defect : 100 %
Equipment Information : Brand / Trade 1 :
Model : BMW
BMW Motorcycle Dealer Accessory Top Case for R 1300 GS Part No. : 77 43 9 443 542 Size : NR Function : NR
Descriptive Information : Approximately 338 dealer accessory top cases may not have been produced by the supplier according to specifications.
Basis for recall population determination: Accessory sales records and parts logistics information were reviewed to determine the number of potentially affected top cases that may have been delivered to dealers or retailed to customers. Recall component difference to non-recall component: The dealer accessory top case may not have been produced by the supplier according to specifications. Production Dates : JUN 24, 2023 – JAN 31, 2024
Description of Defect :
Description of the Defect : 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.
FMVSS 1 : NR
FMVSS 2 : NR Part 573 Safety Recall Report 24E-020 Page 2 Description of the Safety Risk : If the top case detached from the motorcycle, it could become a hazard for road users, and increase the risk of a crash.
Description of the Cause : NR Identification of Any Warning NR
that can Occur : Involved Components : Component Name : Dealer Accessory Vario Top Case for R 1300 GS Component Description : Dealer Accessory Vario Top Case for R 1300 GS Component Part Number : 77439443542 Supplier Identification : Component Manufacturer
Name : TOURATECH GmbH
Address : Auf dem Zimmermann 7-9 Niedereschach Foreign States 78078
Country : Germany 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 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24E-020 Page 3 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. Description of Remedy :
Description of Remedy Program : The locking mechanism of the top case will be reworked to ensure that it is
functioning correctly. Additionally, the description of the locking operation in the Rider’s Manual has been improved, and an insert for the manual with the updated instruction will be provided with each reworked top case. Owner notification is not necessary as potentially affected top cases have not been retailed. How Remedy Component Differs from Recalled Component : Dealer Accessory Vario Top Case for R 1300 GS – part number – 77 43 9 443 542 Identify How/When Recall Condition NR was Corrected in Production : Recall Schedule :
Description of Recall Schedule : Dealer notification is planned to begin and end on February 29, 2024.
Owner notification is not necessary as potentially affected top cases have not been retailed Planned Dealer Notification Date : FEB 29, 2024 – FEB 29, 2024 Planned Owner Notification Date : NR – NR The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24E-020
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported
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© 2023 BMW of North America, LLC. The contents of this document are confidential and should not be shared with third parties for distribution.
TEC617 VARIO TOPCASE
RECALL 24E-020 HAS BEEN ISSUED FOR THE VARIO TOP CASE FOR R 1300 GS
OVERVIEW
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.Bulletin #: AS-13-24A ☐Take Note☒Take Action
☐Retail Operator
☐Sales Pre-Owned
☒Business Manager
☒Parts & Accessories
☒General Manager
☐Sales New Bike
☒Service
☐Administration
Name: Alex Martin
Phone Number: 201-449-8859
Title: Material Planning and Parts Logistics Specialist
Email: alex.ma.martin@bmwna.com
Source: Parts Logistics Date: 03/14/2024Supersedes: -AS-13-24 Description Part Number
Vario Topcase
77 43 9 443 542
© 2023 BMW of North America, LLC. The contents of this document are confidential and should not be shared with third parties for distribution.
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.
RETURN DETAILS
•The image to the right shows the parts as depicted in ETK. Please seethe table below regarding affected / blocked parts.
•Affected parts are all remaining new, spare parts shipped and deliveredto date only.
•Please return all incorrect part(s) to your facing Regional DistributionCenter (RDC).
•Submit for return using a YR26 damage claim with order reason BM2. Avalid 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 sectiondirected to Returns/Claims/Quality.
MORE DETAILS
•TEC617 is valid from February 14, 2024, through April 30, 2024. The deadline for filing a claim under TEC617 isApril 30, 2024.
•All parts must be returned to your facing RDC no later than May 15, 2024.
© 2023 BMW of North America, LLC. The contents of this document are confidential and should not be shared with third parties for distribution.
MORE QUESTIONS?
Aftersales Business Development Manager
Material Planning and Parts Logistics Analyst
Aftersales Marketing Specialist
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AS1724 – Delivery Stop – Vario Top Case for R 1300 GS
Recall 24E-020 has been issued for the Vario Top Case for R 1300 GS
Recall 24E-020 has been issued for the Vario Top Case for R 1300 GS
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.
If you have a top case in your inventory matching the above description, it cannot be retailed and cannot be installed. Please refer to TEC Return (TEC617), issued on February 13th, for instructions to identify and return potentially affected top cases.
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.
Mar 1, 2024
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SEOCONTENT-END