Anyone noticed fuel tank plastic cracking?

**boulder650** · 07-25-09

On my F650GS twin today I noticed on both sides of the fuel tank just under the body color panel the plastic has separated and formed a 1/16" crack for several inches. You have to look close as it is in the molded 90 degree indentation that runs along each side. I didn't think a photo could be taken that would show it so the description is the best I can do. The fuel tank must be doubled lined or something or gas would be leaking. Or maybe this really isn't part of the fuel tank but I will show it to the dealer when I go in for the 600 mile checkup. I have about 750 miles on it and I'm more than a little concerned. Let me know if you see anything similar. Thanks.

**boulder650** · 07-25-09

Photo came out better than I thought it would. Gary

View image in gallery / garage

**paco** · 07-27-09

Gary,

My tank has the same appearance as yours. 5000 miles on the bike with no fuel leaks so far. I will point this out to my dealer at my 6000 mile service.

**craigster** · 07-27-09

I have a 2009 F800GS with the same issue, a stress crack at the seam. Contacted the dealer and they are aware of the problem and it is a warrenty covered item. That said there are no replacement tanks available at this time. A double lined tank thank goodness. <>< Craigster

**jrwooden** · 07-28-09

Damit ............ I think mine is doing it ... on the filler side right in the crease I have a fairly long (3"+) row of "bubbles" where it looks like the plastic is trying to pull apart ....

Sigh................

Craigster ... so it is a double-wall tank?

I guess we can wait for German reinforcements ....................

It does not seem to me that swapping out the tank is going to be a very easy job....
I wonder what the flat rate book gives for labor hours on this?

Thanks,
Jim

**craigster** · 07-28-09

Yes, according to the dealer it is a double lined tank. As big as the separation is gas would be leaking already. I have heard it said before, They sure messed up when they put a three year warranty on this bike.
Just a a thought, maybe add another gallon to the tank while they're at it

<>< Craigster

**Back Roader** · 07-29-09

Originally Posted by craigster

I have a 2009 F800GS with the same issue, a stress crack at the seam. Contacted the dealer and they are aware of the problem and it is a warrenty covered item. That said there are no replacement tanks available at this time. A double lined tank thank goodness. <>< Craigster

Hey CRAIGSTER, how many miles do you have on your bike now ? Just curious as there are no signs of cracking on mine however I am only at 6000KMs (4000miles)

**jrwooden** · 07-29-09

I have only about 5000 miles on mine... and I am pretty certain my tank is starting to go..........

I will stop whining about it if I find out that the "new replacement" tanks have a bit of extra capacity

.... otherwise I reserve the right to bitch-and-moan....

**boulder650** · 07-29-09

I think a new tank is wishful thinking. I bet BMW will consider this a cosmetic problem and refuse to replace the tank. It's probably a plastic encased steel or aluminum tank and as long as the inner tank is fine they'll say no problem. But I could always be surprised.
Gary

**SHU** · 07-29-09

Originally Posted by boulder650

I think a new tank is wishful thinking. I bet BMW will consider this a cosmetic problem and refuse to replace the tank. It's probably a plastic encased steel or aluminum tank and as long as the inner tank is fine they'll say no problem. But I could always be surprised.
Gary

I'd bet against you on that. They replaced my original footpeg rubbers (F800ST) when they wore out prematurely.

I'm trying to imagine the scene: talking to my dealer and him trying to convince me that this is not a defect in original manufacturing. I just can't see it.

...........shu

**craigster** · 07-29-09

I first noticed the cracks at 3000 miles. I now have 4500 miles and the length and hight have increased slow but sure. I hope they do replace this under warranty, my dealer said it was covered and he hasn't let me down yet. I sure bet the engineers that ok'd the tank design and quality control are in deep trouble. Remember, just say no to CRACK"
If your listening pleeeease add at least 1 more gallon of tank capacity. <>< Craigster

**Navaho** · 07-29-09

Is there anything structural about this outer shell or just cosmetic?

**craigster** · 07-29-09

Good question on the structural aspects of the tank. The fact that stress cracks are forming indicates to me that there is some loading on the outer wall of the tank. As far as design it would be interesting to see diagrams of the points off attachment to the frame and what the inner tank connection to the outer tank relationship is. It may just be bad design or bad material choice or quality. Reminds me of the wheel rim design. To wide and to soft a material. That's why they bend. "not that I'm bitter"

I sure hope some big German engineer does't come to my house someday all mad and stuff. PEACE <>< Craigster

**paco** · 08-01-09

I took my F650GS by BMW of Indianapolis today. They will order and replace the fuel tank under warranty....no questions asked. They have not seen this before and said there is no question this a warranted item.

**BMWHillbilly** · 08-01-09

Damn...I just went and looked and I have the crack on my tank too. Looks just like the pic posted earlier and on the same side. I will be going to my dealer next week and let them see it. Sheesh...how many parts am i gonna have to replace on this thing before I crack 5000 miles??

LOVE the bike though. I'm just tired of going to the shop every time I turn around....

things replaced so far:

Fuel Sensor
Water pump
coolant hose
fuel tank?

**jrwooden** · 08-01-09

I'm wondering if any "design changes" have been made in the tank?

I'm really not excited about getting a new tank that has the same potential issue as the one I've got now ... anybody know?

Is the P/N of the new tank different?

**craigster** · 08-01-09

Paco, My dealer said the same thing as far as the tank being under warranty. The problem they had was there isn't any tanks to be had anywhere at this time. Let me know if they come up with a tank. "Tanks"

<>>< Craigster

**paco** · 08-02-09

Craig,

I'll update the thread when I find out about the delivery time for the tank. I'm considering filling the crack with some black caulk or sealant for aesthetics and to keep moisture from getting between the outer and inner liners.

**Bushwhacker** · 08-02-09

My bike has 843 miles on it and has never been off pavement and has cracks running along both sides of the tank.

Links to full size images -

Left side -

http://i18.photobucket.com/albums/b1...ftSideTank.jpg

Right side -

http://i18.photobucket.com/albums/b1...kRideSide2.jpg

-

-

**DockingPilot** · 08-02-09

This problem will big a huge hit to BMW in a $$ sorta way if this is widespread.
Cuz this aint gonna be cheap to replace.

Makes you wonder, how they survive with all the warrenty work they get billed for.

**Josh9399** · 08-04-09

Well I checked and mine is cracked / starting to crack too 900 miles. Grrreat ! But hell if they put a new one in Im bettin' it will do the same thing. Wonder if they will give a new one up without an install and I'll put it in when it gets worse , I get tired of looking at it , or want to sell it ? Ha what am I thinking......

**Richard230** · 08-04-09

Don't you just love plastic?

At least it doesn't corrode when exposed to foggy, salty air.

**notacop** · 08-04-09

Wow, you GS guys are really getting a spotty deal with fuel tank failures. Kinda make you wanna go somewhere remote with no water just to be adventureous.
Remember a few of the first 800 had expanding fuel tanks due to a breather line kink and some folks rubbed the rear tire through the tank.
Fun with your new bikes from BWM!

**Navaho** · 08-04-09

Originally Posted by notacop

Wow, you GS guys are really getting a spotty deal with fuel tank failures. Kinda make you wanna go somewhere remote with no water just to be adventureous.
Remember a few of the first 800 had expanding fuel tanks due to a breather line kink and some folks rubbed the rear tire through the tank.
Fun with your new bikes from BWM!

I see this as a minor cosmetic defect, just a partial failure of plastic body art, not a structural tank failure. And it is certainly not something that would leave you stranded

. The POS chains might, though

I have noticed a 3" long crack (on my tank plastic

) but I am not worried about it. And I would assume that the tank construction is corrosion proof.

**jrwooden** · 08-05-09

Mine is growing rapidly ... a week ago it was only noticable on close inspection and perhaps 2" long....
Now it is quite easily noticed and runs almost the entire lenght of the "ridged" portion of the tank on the filler side...

Tell me again ... this IS a double-wall tank right? ;-/

I guess I need to call the dealer and figure out what the plan is .... I do want to make sure the replacement is an "improved" deisgn ... otherwise I'll just put JB-Weld on it till a GOOD tank comes along................

sigh............

**paco** · 08-05-09

I think it is interesting (

) that owners are now just starting to see this problem, and still relatively few of us (in comparison to the numerous stalling in the rain complaints). It makes me hopeful that maybe the problem is confined to a particular injection molding production batch or a specific batch of raw material. Then again... the problem may be widespread and we are just the observant ones.

**EmmBeeDee** · 08-05-09

Originally Posted by paco

Craig,

I'll update the thread when I find out about the delivery time for the tank. I'm considering filling the crack with some black caulk or sealant for aesthetics and to keep moisture from getting between the outer and inner liners.

Might be better to use the plastic bumper epoxy - it works really well on that kind of repair, temporary or not.

Here's an article on "Repairing The Plastic Bumper Cover On A 2004 Mercedes Benz ML320" which is probably only slightly more expensive than a F658/800GS fuel tank.

This page lists some products you might find more useful than caulk or sealant.

**lskbike** · 08-05-09

Add my bike to the list of those that have cracks running along both sides of the "gas tank" outer liner.

My bike has 2,194 miles on the odometer and it has not, as yet been off road. I read about these cracks on this website then went out to my garage and removed my Jesse's bags! Wow! There they were on both sides. I feel confident that the cracks are "cosmetic" but I will expect BMW to do something about them... Next time I am at my dealer I will point them out to the service manager and ask him what is the cause and is BMW planning a recall. It will be interesting what BMW's position will be when all of us with these cracks go to our respective dealers and request repair!

LSKBike

**cyclynnut** · 08-05-09

My husband was after me since first announced that the twin was coming to ride one and get it. I waited until June so all of the 'bugs' would be worked out. Found out after I got her home that she was built June '08. I stalled on my first 800 mile trip in the pouring rain, had the hose, fuel sensor, BMW Vario case replaced and now the cracking gas tank. I am trying to love this bike-I have always ridden cruisers. I do love the way it handles but I have added Rox risers, SW Tech engine guards with pegs and Touratech seat and still not as comfortable as the cruisers. Have 6,000 miles since June 10 trying to be patient. I am not pleased with the quality-seems QA folks will be in big trouble. I have enjoyed reading all the information on here. You have been a big help and thanks for listening.

**ebrabaek** · 08-05-09

Originally Posted by DockingPilot

This problem will big a huge hit to BMW in a $$ sorta way if this is widespread.
Cuz this aint gonna be cheap to replace.

Makes you wonder, how they survive with all the warrenty work they get billed for.

Charging $ 14000 for a enduro bike......

Erling

**BMWHillbilly** · 08-05-09

Originally Posted by cyclynnut

My husband was after me since first announced that the twin was coming to ride one and get it. I waited until June so all of the 'bugs' would be worked out. Found out after I got her home that she was built June '08. I stalled on my first 800 mile trip in the pouring rain, had the hose, fuel sensor, BMW Vario case replaced and now the cracking gas tank. I am trying to love this bike-I have always ridden cruisers. I do love the way it handles but I have added Rox risers, SW Tech engine guards with pegs and Touratech seat and still not as comfortable as the cruisers. Have 6,000 miles since June 10 trying to be patient. I am not pleased with the quality-seems QA folks will be in big trouble. I have enjoyed reading all the information on here. You have been a big help and thanks for listening.

I hear ya. I just see it as first year bugs and it does not deter me in any way. I have had a few things replaced and yes, my tank is cracked.

I came from cruisers too but i find this bike set up is alot more comfy for distance than any of my cruisers were. I LOVE this bike even with all the quirks.

They will get ironed out.

**dadayama** · 08-05-09

Just getting around to reading this thread....

you all freaked me out... i just went out in the rain to look in the garage at my sweet princess, and there are no cracks at all! Fortunately !!!!

Almost 7000 miles, bought her in September 2008.... (2009 Model)

I'll keep an eye on it... but if i was you all i'd be raising hell!

Peter in OKC, OK

**EmmBeeDee** · 08-06-09

Originally Posted by dadayama

Just getting around to reading this thread....

you all freaked me out... i just went out in the rain to look in the garage at my sweet princess, and there are no cracks at all! Fortunately !!!!

Perhaps that's a clue? Garage Princesses don't get the problem? Our two are in a garage all the time if we're not riding (except when traveling, of course) and neither one shows signs of gas tank splitting at 20,000+ kilometers.

The one which are splitting - could it be UV/sun damage?

**Bushwhacker** · 08-06-09

Originally Posted by EmmBeeDee

Perhaps that's a clue? Garage Princesses don't get the problem? Our two are in a garage all the time if we're not riding (except when traveling, of course) and neither one shows signs of gas tank splitting at 20,000+ kilometers.

The one which are splitting - could it be UV/sun damage?

If it is then the Dealership left it out. I have only had it a couple of months.

**blackie** · 08-06-09

Picked up mine in May 08, prolly one of the initial runs, no cracking

**dadayama** · 08-06-09

Originally Posted by EmmBeeDee

Perhaps that's a clue? Garage Princesses don't get the problem? Our two are in a garage all the time if we're not riding (except when traveling, of course) and neither one shows signs of gas tank splitting at 20,000+ kilometers.

The one which are splitting - could it be UV/sun damage?

Well actually i commute to work every day. So she sits out in the hot Oklahoma sun all day. I put her in the garage at night to keep her from getting stolen.

**lskbike** · 08-06-09

My 09 F650GS with 2,149 miles on the odometer was purchased in September 2008. It is always garaged except for a few overnights outside in warm weather while travelling. As I posted previously, it has the cracks on both sides of the "tank". They aren't "open" very much, as yet, but they are clearly there. After reading all the posts so far, there doesn't seem to be much rhyme or reason as to which bikes get them or why!!!

LSKBike

**cyclynnut** · 08-07-09

Mine is garage kept except on trips and I cover at night on them. Don't think that is it-even if it were, it should not happen. A bike is going to be in the weather if it is ridden.

**EmmBeeDee** · 08-07-09

Originally Posted by cyclynnut

Mine is garage kept except on trips and I cover at night on them. Don't think that is it-even if it were, it should not happen. A bike is going to be in the weather if it is ridden.

I realize it shouldn't happen -just wondered if there were circumstances which caused it to happen quickly on some bikes.

The F650GS single we have has a plastic fuel tank and I've never had to think about it in 6 years of use, aside from filling it.

**cyclynnut** · 08-07-09

I think the cracking is just on the new twin 650. I have had mine less than two months so pretty certain it is a production issue. Thank goodness it is not the tank that actually holds the gas. My dealer said they do not have a beginning or ending on when this defect occurred so no tanks are available yet to replace the cracked ones.

**paco** · 08-14-09

BMW Indy has received a replacement tank for my F658GS. I have scheduled an appointment for the last week of August to have my tank replaced. I will provide an update on how it the replacement goes and if I can detect any difference in the molding design or quality.

**are12c** · 08-16-09

Originally Posted by cyclynnut

I think the cracking is just on the new twin 650. I have had mine less than two months so pretty certain it is a production issue. Thank goodness it is not the tank that actually holds the gas. My dealer said they do not have a beginning or ending on when this defect occurred so no tanks are available yet to replace the cracked ones.

Nah. My F800 is showing signs as well. The local dealer has created a repair order and I'll make an appt. as soon as the replacement comes in.

**Bruce.B** · 08-18-09

I have an early F800GS (end of Sept 200

and don't see any evidence of cracking. Just to be sure I asked the dealer to check it also and they found the same thing I did: the tank looks fine.

Bruce
Santa Fe, NM

**Bpj100** · 08-19-09

Purchased mine in April 09 and sure enough it is starting to crack out under the fill cap, as stated...I guess mine is not perfect ...

**sarkmych** · 08-21-09

I just put the first 1000kms on it and I will surely go home today after work and check that out. I'll let you know what I find.

**lskbike** · 08-23-09

I took my bike in yesterday to my dealer (BMW Motorcycles of Louisville, Ky) to do the recall for the fuel sensor.. My gauge actual failed before I knew there was a recall. I also showed them the cracks in my fuel tank. On my bike, the crack is running along both sides the full length of the tank. The left side is worse than the right.

They seemed a bit concerned. I was asked if I had noticed any gas leaking from the cracks or had I noticed a strong smell of gasoline at any time. I responded that I hadn't. They advised me they hadn't seen this on any other bikes as yet but stated that most riders probably wouldn't notice them, at least until they got wider. They were obviously concerned about the safety implications of this problem. They took photos and were going to send them on to BMW. I talked to the mechanic and service manager and I told him about this list! I advised him that several people had reported these cracks on the F800Riders.org site but none had reported that they were leaking gasoline. The mechanic and service manager seemed to be somewhat relieved when I told them this!!!

The mechanic wanted me to let all of you know that if you have these cracks in your tank to be sure to contact your dealer and show them. That way BMW will know the "numbers" and hopefully will address a cure ASAP.

Just as a side...I am very pleased with BMW of Louisville. I have no connection to them except that they have taken care of me and my bikes for years! As I came in for service on at 9 AM on Saturday, the service manager was on the phone talking to someone riding a BMW that had quit in Berea, KY. The bike apparently was still under warranty so the owner was getting it towed to Louisville. Later in the day, I was talking to the owner, Jeff Cooke, when the service manager came up and advised Jeff about the bike being towed from Berea and that they may need to use a bit of overtime to fix this guys bike as he was on a trip. Jeff immediately said, "that's fine!" I was glad to witness that!

At any rate, if you have the cracks in your gas tank, be sure to show them to your dealer and maybe we can expedite BMW's taking care of the problem.

Also, if anyone's bike starts to leak gasoline...be sure to post it on this list so all will know!!! We can then get the bikes out of our garages and get them back to the dealers...

Happy Trails!!!

LSKBike

**Bushwhacker** · 08-23-09

Not only did I show my dealer the cracks in the tank on my bike, I also showed them cracks in the tanks on the two F800GS Bikes they had on the show room floor.

**lskbike** · 08-23-09

Good idea Bushwacker... I didn't think of that when I was at the dealer yesterday...

LSKBIKE

**YetiGS** · 08-23-09

Count me in for the cracks too. On both sides. About 3k miles on the bike. I'll take mine to the dealer on Friday, but I'm going to enjoy riding it in the meantime,

**sarkmych** · 08-24-09

Originally Posted by sarkmych

I just put the first 1000kms on it and I will surely go home today after work and check that out. I'll let you know what I find.

Just inspected it ahter my first 1000kms and no cracking that I can see. I'm taking it to the dealer for its 1000km check-up and I will ask them what they know of this phenomena.

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