2002 BMW F650CS Recalls Canada & USA – Major League Recalls
2002 BMW F650CS Recalls — Canada & USA
Summary
The 2002 BMW F650CS has 7 recalls, with the most serious being a rear brake caliper that can separate from its mount, rupture the brake line, and cause either a complete loss of rear braking or a sudden rear wheel lockup.
The drivetrain carries several concerns. The front drive belt wheel is secured by a hex nut that may not have been tightened to the correct torque during assembly, and that nut can back off during riding, putting the belt drive at risk. The rear drive belt wheel can also crack and eventually fail, causing the drive belt to come off and leaving the rear wheel with no drive power. Prior repair attempts on the belt wheel did not fully resolve the issue, as replacement wheels installed under an earlier repair may also crack. On the fuel side, the plastic flange on the fuel pump can become brittle if it contacts acidic substances such as battery acid or certain cleaning products, and may eventually crack and allow fuel to leak from the tank.
On certain motorcycles, if the plastic fuel pump flange comes into contact with a sufficient amount of acid or chemical compounds containing acidic elements, such as battery acid or certain cleaning products, the flange may become brittle. Over time, the flange may crack, and eventually allow fuel to escape from the fuel tank.
Safety Risk
No risk description available.
Remedy
Dealers will install an acid-resistant cap over the fuel pump flange.
On certain motorcycles the rear caliper attaching screws are under torqued. This could cause the caliper to separate from its mount, potentially rupturing the brake line and causing a loss of rear braking. It is also possible in such a case for the caliper to cause rear wheel lock up adversely affecting the dynamic stability of the motorcycle.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and correct the torque of the rear caliper screws. This is an extension to recall 02-099.
On certain motorcycles, the hex nut that secures the front drive belt wheel to the gearbox output shaft was torqued to a value less than specification during the vehicle assembly process. As a consequence, the nut could loosen during vehicle operation. If this happens, the belt wheel would itself loosen on the output shaft, resulting in damage to the internal splines of the wheel and to the external splines of the output shafts as the vehicle is operated. Over time, the splines could be damaged to the extent that the output shaft would no longer operate the drive belt, resulting in a loss of drive capability at the rear wheel.
Safety Risk
No risk description available.
Remedy
Dealer will secure the front drive belt wheel to the gearbox output shaft by utilizing a new set of components, including a redesigned front wheel pulley. Also the main-shaft splines will be inspected for proper dimension and replaced is it is out of specifications.
On certain motorcycles, the rear drive belt wheel could crack and eventually fail causing the drive belt to derail. This would result in a loss of drive to the rear wheel. Motorcycles previously repaired under recall 2002185 using the current replacement rear drive belt wheel are also affected. The replacement belt wheels installed for this previous recall may also crack.
Safety Risk
No risk description available.
Remedy
Dealer will replace the drive belt wheel with a wheel that has additional reinforcements (soldering) in the critical deformation zone.
On certain vehicles, the rear drive belt wheel could crack and eventually fail causing the drive belt to derail. This would result in a loss of drive to the rear wheel.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the rear drive belt wheels for certain production numbers. Only wheels with those specific production numbers will be replaced.
On certain motorcycles, the hex nut that secures the front drive belt wheel to the gearbox output shaft was torqued to a value less than specification during the vehicle assembly process. As a consequence, the nut could loosen during vehicle operation. If this happens, the belt wheel would itself loosen on the output shaft, resulting in damage to the internal splines of the wheel and to the external splines of the output shafts as the vehicle is operated. Over time, the splines could be damaged to the extent that the output shaft would no longer operate the drive belt, resulting in a loss of drive capability at the rear wheel.
Safety Risk
No risk description available.
Remedy
Dealers will check the torque of the hex nut and adjust is necessary.
On certain motorcycles the rear caliper attaching screws are under torqued. This could cause the caliper to separate from its mount, potentially rupturing the brake line causing a loss of rear braking. It is also possible in such a case for the caliper to cause rear wheel lock up adversely affecting the dynamic stability of the motorcycle.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and correct the torque of the rear caliper screws.