2009 F800GS Out Of Commission

Discussion in 'Parallel Universe' started by outpostbabu, Jul 3, 2010.

  1. outpostbabu

    outpostbabu Been here awhile

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    Had a little problem with my 2009 F800GS (23,000 miles). I was riding along and got two surges, then a brief clunking noise and then it shut off. The shop discovered the timing chain had come off. They were worried about engine damage caused by the chain being loose but there was no apparent damage. However when they got the engine back together (two weeks later, parts from Germany, etc), the engine is now knocking. They think the whole engine will have to be replaced. This means at least another two weeks without my primary transportation.

    Has anyone else had such a severe problem with a relatively new bike? All the work is under warranty of course but at this point I'm a little pissed with the quality of the BMW and not being able to ride for at least a month. For those that did have problems of this sort, particularly with BMW, what options did you have? Is it worth it to talk to BMW NA?
    #1
  2. outpostbabu

    outpostbabu Been here awhile

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    Mods please move to the new GS twins forums :evil
    #2
  3. outpostbabu

    outpostbabu Been here awhile

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    <a href="http://www.flickr.com/photos/fortunemegastore/4728271525/" title="F800GS In Pieces by outpostbabu, on Flickr"><img src="http://farm2.static.flickr.com/1254/4728271525_f308c1f8c8.jpg" width="375" height="500" alt="F800GS In Pieces"></a>

    <a href="http://www.flickr.com/photos/fortunemegastore/4728916278/" title="F800GS In Pieces by outpostbabu, on Flickr"><img src="http://farm2.static.flickr.com/1006/4728916278_e60bfeecfe.jpg" width="375" height="500" alt="F800GS In Pieces"></a>
    #3
  4. JoelWisman

    JoelWisman Long timer

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    Yours is the only rotax twin I have ever heard of spitting a timing chain, internally or on the web.

    This was likely caused by a defective chain, chain tensioner, oil problem, chain guide problem, or a problem with the sprocket.

    I'm dying to know which. Any chance your tech can tell you what they found and take pictures?
    #4
  5. outpostbabu

    outpostbabu Been here awhile

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    I'll be over at the shop on Tuesday to get more details and find out what they plan to do. I'll let you know then.
    #5
  6. WOLVERINE

    WOLVERINE Keep her pinned!

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    What kind of knocking sound did it make after reassembley? Curious!
    #6
  7. EnderTheX

    EnderTheX Dirt Rider

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    Good luck man... Try not to be too unhappy because you may get a brand new engine for free! Also keep us posted on the results. :freaky
    #7
  8. Nictrolis

    Nictrolis Been here awhile

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    Yeah, get lots of engine pics! The good, the bad - and the ugly.
    #8
  9. outpostbabu

    outpostbabu Been here awhile

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    I'll be going over to the dealership in a bit but to summarize how this came about: I was cruising down the interstate late one night, stopped to get some gas, and got back on the interstate. As I was accelerating down the on ramp, I felt two small surges. The bike had been running perfectly up to this time, no weird noises, nothing. I thought the surges were a little odd so looked back to make sure the the gas lid was closed and made my way across the lanes of traffic to the HOV lane. As I was cruising in the lane I suddenly hear a weird metallic noise and the engine rpms immediately drop to zero. I coast up the HOV exit ramp and make it all the way to the top before pulling over to the side of the road. I had the stalling problem before and so I've had the bike cut out on me and successfully restart. I tried to restart it and it made a very harsh metallic hammering sound. I knew that was really bad so I didn't mess with it any more, waiting for 2 hours on the side of the interstate for BMW Roadside to show up and had it towed to the dealer. So the failure came with no warning. This is a bike I'd ridden from Atlanta to Montana, down to Utah, and back again with no problem. I was thinking about riding it to Mexico later this year. I'm very happy this didn't happen on a long trip!
    #9
  10. outpostbabu

    outpostbabu Been here awhile

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    I wasn't at the dealership after they rebuilt the engine and tried to start it up so I'm not sure what it sounded like. If I can hear it today I'll let you know.
    #10
  11. sealteam4

    sealteam4 Adventurer

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    I don't know if this is similar to happened to you. I was riding, I was in fourth gear and then I down shifted to third when at that moment I heard a sound like if a small rock hit the metal skid-plate on my bike, immediately after that my engine shut off. I was riding on pavement, no stones or rocks, it was something internally. I was able to turn the bike on again and keep riding I haven't had any problems since but am still worried.
    #11
  12. awshouse

    awshouse Downwardly mobile

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    that sucks! I took my 09 for the sprocket/chain recall and charcoal hose routing recall today and scheduled the work. They offered me a loaner bike. Having never previously purchased a new bike this was a pleasant surprise. Maybe you should inquire? This was at Ride West BMW in Seattle. . . not sure how general the practice may be. My last BMW was a 72 and on the east coast...
    #12
  13. outpostbabu

    outpostbabu Been here awhile

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    That sounds like something worth getting checked out, especially while/if you're still under warranty. My experience was a little different. The sound wasn't like the pinging of a stone on the skid-plate it was more like a metallic thud.
    #13
  14. outpostbabu

    outpostbabu Been here awhile

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    Yeah I've gotten a loaner bike before from my dealer and they're a good bunch of guys. They haven't offered a loaner and I haven't asked. Technically I can drive the car but that sucks because I commute 50 miles a day and so I'm paying 2x for gas now. Right now it seems its the BMW rep that's taking up all the time with no movement towards a solution so I can't really blame the shop. I went over there yesterday to look at the bike and see what the story was. The bike was put away somewhere, they're not doing anything else with it until they hear from BMW but they're aiming for getting the whole engine replaced (still)...
    #14
  15. GeorgeinVA

    GeorgeinVA Beemers Uber Alles

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    Can't hurt. BMW needs to hear that you r disappointing with them. If you say nothing then nothing will change.
    The noise after rebuild is very concerning. Do you have a list of parts that were replaced? I believe the F800 is an interference motor so you should have some valves and maybe a piston.
    Was any engine work done prior to the failure?
    As for valve gear reliability, yours is the fist F800 I have heard of as well, can't say the same about the new K1200 chains.
    #15
  16. jasonTDI

    jasonTDI TDI Guru

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    The metallic noise would have been the pistons smacking the valves. They were bent and they didn't disassemble the bike far enough to find this. Sounds like the tried to time it and slip in a chain/tensioner. Make them replace the engine.
    #16
  17. outpostbabu

    outpostbabu Been here awhile

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    I haven't seen a list of the parts but the timing chain and the camshaft gears were replaced and I'm guessing the hydraulic tensioner was likely replaced with them. They removed the pistons to look for damage and thought there was none but obviously something is very wrong.

    I called today to get an update. Its very frustrating because the BMW rep is not readily available. They're always waiting on him to call back. The mech said BMW was "freaking out" because a new engine is $10,000 and that he will come by next Tuesday or Wednesday to look at the bike again. The bike has been in the shop since June 16th... I asked for a loaner in the interim, will see what I get tomorrow.

    I'll be calling BMW NA tomorrow.
    #17
  18. outpostbabu

    outpostbabu Been here awhile

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    Called BMW NA today to see if they could move things along. The customer relations people are not really any help at all. I told them the BMW rep only comes out once a week, if that, that the bike has been in the shop nearly a month with no resolution in sight. Their response was that the reps are very busy and that they have no direct contact with the rep but that they would be happy to file my compliant. I asked them what good that would do towards fixing my bike and she said nothing but that the company uses these complaints internally and that it would be attached to my file. That's all useless to me. :baldy
    #18
  19. Ducksbane

    Ducksbane Quaaack!!!

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    Why don't you get an email address for BMW NA customer relations so that the other US inmates can email them and express joint displeasure and concern. Everybody wants to be looked after if somethings goes wrong ... right?

    Look on it as sort of "Free Outpostbabu" campaign. :shoot

    Good luck!
    #19
  20. outpostbabu

    outpostbabu Been here awhile

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    I've looked around for BMW Customer Relations email addresses online and not surprisingly nothing comes up. It's a good idea and I'd like to email them myself so I'll keep trying to find names and contact info. I don't suppose anyone reading this has emailed them before and have an address handy?
    #20