Bmw F650gs Dakar 2002

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• Motorcycle front wheel separation investigation # PE09026

  This pe was opened after nhtsa received 3 voqs concerning alleged front axle separations on certain bmw f650 gs model motorcycles sold for use in the united states (the subject vehicles).Complaints involving motorcycles in non-us markets are not counted in this total.After gathering additional information about this subject, we are now aware of four confirmed incidents involving model year 2001-2003 subject vehicles.All four bikes were built before september, 2002.Of these, two involve my 2001 bikes and the other two, mys 2002 and 2003, respectively.The incidents occurred in 2002, 2003, and two in 2008.In each instance, the lug fractures are forced fractures rather than fatigue-related.Between october 1999 and september, 2002, bmw built approximately 4,300 subject vehicles.After september 12, 2002, all f650gss were built with reinforced lower fork tubes to reduce, according to bmw,"the possibility of any significant fracture that could occur at the fork leg axle lug area"during a crash.Bmw took this action because the subject vehicles are designed for off-road use where crashes (many minor) are common and did not want riders to have to deal with a broken fork as a result.Currently, there is no data conclusively establishing that the subject fork lugs are separating before an alleged crash occurs.Additionally, the infrequent, sporadic, and random nature of the failures fails to establish a defect trend currently exists.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.The agency will take further action if warranted by the circumstances.
  

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The front axle detached from the rhs fork leg while traveling at approx 50 kmh down a washboard section of a gravel road. I had time to lock the rear brake which slow me down considerably before falling down to the right. Other parts of the motorcycle were damaged.. Ie: front turn signal, windshield, large side panel, handlebar and hand protector, rhs pannier. I did not pursue the matter at this time, but heard of similar incident that have happened in australia, usa involving the pre 2003 model. *tr

1. "wobble" in the front forks of my f650gs for about 1 week. Then a catastrophic failure of the fork casting from the wheel hub of the front right side of my 2002 f650gs. I was going approximately 10 mph through a round-about in woodinville, wa when it failed. 2. After coming out of a round about north bound on the woodinville-redmond road in woodinville, wa going about 10 mph. The casting failed. So far, there is damage to the bike, my helmet, my gloves, my riding jacket (with body armour), and dislocated shoulder to my person with potential tendon and ligament damage to my shoulder. 3. So far the bike is in the local bmw motorcycle dealership (ride west seattle) and is waiting for the estimates. *tr

Tl*the contact owns a 2002 bmw f650gs. While riding at 65 mph, the motorcycle, wobbled, and proceeded to throw the contact from side to side. The handle bars disconnected and no longer controlled the steering. The contact was thrown from the motorcycle. There was no impact, but the vehicle slid across the asphalt and the entire front wheel detached from the vehicle. The contact sustained fractures to her left forearm and hand. A police report was filed. She was airlifted to the hospital. The failure mileage was approximately 30,000. Updated 10/28/08 *bf updated 10/30/08. *jb

The front axle detached from the rhs fork leg whilst traveling at approx 40kms/hr down a grassy lane way in a vineyard. The result was a very heavy fall to the right into the ground headfirst & subsequent medical attention for a badly bruised neck and, the doctor's tell me "soft tissue damage to the brain" i completely destroyed a bmw phase iii helmet in the process. I bring this to your attention at this time even though this incident occurred in australia due to the recent incident already reported to you & shown now on your public files. Bmw australia claimed to me at the time that they were unaware of any other such incidents worldwide. I did not believe them at the time but was involved in a major project and could not afford the time away from the project to pursue the matter. The parts from my incident were sent to germany for stress testing and so there are records of the incident even though it was not strictly on a public roadway. Bmw claimed to me that the testing did not show any failure in the metals of the rhs fork leg and that i must have hit something which i did not. I noted at the time that a replacement rhs fork leg supplied in the repair looked different to the one which was removed but i have only just been made aware they changed the design of the fork leg during early 2003 and all machines produced post june 2003 are fitted with the revised casting. I am now also aware of between 7 and 10 similar incidents mostly in the usa. I would be pleased to provide further information if you consider it would be helpful to you. I am a motor cyclist with 35 years and in excess of 1 million kms experience in all weather and all road conditions. There appears to be a pattern of denial in the response of bmw to each of the people who have suffered an incident of this type with the f650gs and it concerns me greatly that if some commonsense does not occur others will also be injured or die. I prefer that my details remain confidential. *tr

Motorcycle engine surged which caused bike to accelerate suddenly and without warning. *tt

Rear view mirrors of bmw f650gs motorcycle fold back at highway speeds in temperatures above 85 degrees. This causes loss of ability to see behind vehicle. Mirrors will not stay adjusted.*ak

The fuel tank problem is a defect or small crack in the plastic. Fuel seeps out and puddles under the seat. I plan to save the old part when the dealer fixes teh problem under warranty. On an internet discussion site i saw two other instances of this problem with this motorcycle and year. The engine/fuel injection problem is stalling. Motorcycle will run fine for many weeks and then it will stall at any speed intermittently. Once the motorcycle is shut off (key in off position) and turned back on it will start and run fine. There is slight surging problem too. This surging problem is the engine not keeping a constant speed when the throttle is held in a fixed position.