The 2004 BMW R1200GS has 9 recalls, the most serious being several issues that can cause brake failure, fuel leaks, or a loose rear wheel, any of which can result in a crash or fire.
On the brake side, an o-ring seal between the anti-lock brake sensor and the rear axle housing can leak differential oil onto the rear wheel and brake disc, reducing braking effectiveness. Under rapid, repeated hard braking, the brake system can develop excess pressure that temporarily disables the anti-lock function, raising the risk of a skid. The front anti-lock brake sensor cable can also be routed incorrectly during service, which may compromise the anti-lock system. A separate issue involves the hand protector on the handlebar: if it twists into contact with the brake lever, it can hold the lever in a partly engaged position and interfere with braking.
On the fuel and drivetrain side, corrosion can cause the fuel pump controller to fail, cutting engine power while riding. A cracked fuel pump flange can allow fuel to leak while the engine is running, creating a fire risk. The rear wheel flange's threaded holes can crack, allowing the wheel bolts to gradually back out and the wheel to loosen.
Two lighting recalls round out the list: the front turn signals on certain motorcycles were installed in an incorrect location, and on motorcycles with dealer-installed accessory turn signals, the lens may be too small, both of which can reduce how clearly the rider's intentions are visible to other road users.
At a glance
What can fail
The fuel pump flange may crack, causing fuel to leak while the engine runs.
What the fix does
BMW will mail you instructions to have a dealer replace the fuel pump and auxiliary fuel pump with improved versions.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
Some motorcycles have dealer-installed turn signals with lenses that are too small to meet safety standards. This could make the motorcycle less visible to other road users and increase crash risk.
What the fix does
Dealers will replace the accessory turn signals with factory-standard indicators that meet safety requirements.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The threaded holes in the rear wheel flange can crack if bolts are over-tightened during service. Over time, bolts may back out, causing the rear wheel to loosen and reducing motorcycle stability.
What the fix does
Replace the aluminum rear wheel flange with a steel flange.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
If the hand protector twists out of position, it may contact the handlebar lever and hold it partly engaged, which can impair brake function and increase crash risk.
What the fix does
BMW will send you an instruction insert and two stickers to properly position the hand protector, or your authorized dealer can install them.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The front turn signals are positioned incorrectly, so other riders and drivers may not clearly see when you intend to turn, raising the risk of a collision.
What the fix does
Dealers will replace the turn signal base to position the signals correctly.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
Under very hard, rapid, repeated braking, the brake system can build up excess pressure that temporarily disables the ABS. This increases crash risk in certain driving conditions.
What the fix does
Dealers will install a special banjo bolt with a flow restrictor on the front brake line to prevent overpressure.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The front ABS sensor cable may be routed incorrectly during tire changes or brake work. If misrouted, it can rub against the brake disk. Severe chafing could disable the ABS system.
What the fix does
Dealers will install additional retaining clips on the ABS sensor cable to keep it properly positioned.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
Water can enter the space under the fuel pump's electronic controller. Corrosion on the plug contacts can follow, causing the fuel pump to fail and the engine to stop.
What the fix does
The dealer will replace the seal protecting the fuel pump electronics.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The rubber seal between the antilock brake sensor and rear axle housing may have been damaged during assembly. If damaged, brake fluid can leak onto the rear wheel and brake disk.
What the fix does
Dealers will replace the rubber seal between the sensor and rear axle housing.
Summarized — see the official notice for exact wording, dates, and contacts.
