Less than a year since BMW Motorrad started delivering their next-generation R 1300 GS to customers, the German manufacturer has announced a new recall related to issues with the semiconductor starter relay. It is estimated that a total of 1,582 units in the United States and around 25,000 units worldwide produced between July 14th, 2023 – March 18th, 2024 are potentially affected.

According to the safety report filed with the National Highway Traffic Safety Administration (NHTSA) the starter relay is enclosed in a housing which was produced with an insufficient injection molding process. This manufacturing defect could make the housing susceptible to damage during motorcycle assembly or a dealer maintenance visit, making it possible for moisture to enter the unit. In certain environmental conditions, this could lead to corrosion of internal electrical contacts in the relay. 

Leakage of current between corroded contacts could result in components heating up. This could lead to heat damage (scorching damage/smoke development) on the starter relay. In rare cases, this could increase the risk of a thermal event or a fire. BMW states riders should be wary of warning signs such as the starter motor turning on its own, odor of overheating electric components, and obviously, smoke.

Recurring Issue

This is not the first recall related to the starter relay that the R 1300 GS has had to endure since it was released in 2023. During launch events for the bike in October 2023, BMW became aware of several issues involving the starter relay, such as no-start conditions and starter motors rotating by themselves. The root cause was identified as moisture reaching the electronic components due to an insufficient injection molding process involving the relay housing. 

After issuing a Service Action in November, several incidents in non-US markets continued, including the smoldering of the starter relay on a press bike and additional field incidents in which starter relays overheated or caused a fire. These parts were requested to be returned for analysis. It was determined that a visual check for damage, as detailed in the November Service Action, was insufficient.

In February 2024, BMW decided to conduct a voluntary recall by replacing the starting relay’s plastic cover, but that wasn’t too effective as problems have continued to persist. On July 18, 2024, BMW decided to conduct this new voluntary safety recall. As of now, there are reports of the new recall impacting around 25,000 units of R 1300 GS globally – all produced before March 18, 2024.

How To Get It Fixed

On all the recalled R 1300 GS models, BMW Motorrad will replace the starter relay free of charge from a semiconductor configuration to an electromagnetic configuration. A necessary software update will also be implemented. According to BMW, the starter relay holder, updated to include preassembly with the improved relay housing and wiring harness, was introduced at the motorcycle assembly plant on March 19, 2024, so the recall only affects units produced before then.

As per the information BMW North America sent to ADV Pulse, this issue is a  recall with a ‘Stop Sale’ directive on new bikes until they have had the issue addressed at the dealer. However, BMW clarified it is not a ‘Stop Ride’ directive, which means the current owners can continue to ride but should get in touch with their respective dealers to see if their bike is affected.

According to the safety report, owners will be notified by First Class mail and instructed to take their motorcycle to an authorized BMW motorcycle dealer to have the remedy performed for free. If this condition were to occur to a potentially affected motorcycle prior to this recall, the remedy would be covered by the BMW New Vehicle Limited Warranty program.

Owners may also contact BMW customer service at 1-800-525-7417 and refer to the NHTSA recall #24V-557 or go to www.safercar.gov.