OK here's my story, I've been thinking of getting an adventure bike, one bike to do it all. And I am leaning towards the 800 GS. It seems to be just what I need. But after researching all the info I can find I'm concerned about all the problems that I have read about. Like chains and sprokets needing replacing, wheel bearings going bad, fuel pumps going out, axles replaced, gas tanks cracking, fuel gage misreading, Etc. ETC. I can't afford a new one so I looking at a 09 or 10 which may not have any warranty left.
So, I want you 800 GS owners to ease my mind, Is it as bad as it sounds, or do most of you not have any problems. I really want this bike but not if I'm going to have constant problems.
I have an 09 built in 7/08. It had issues the first year and all were fixed under warranty, as I expect all were.
As to the issues you mentioned, the original chain was recalled and replaced with a better one. Not DID quality but it won't break on you. The sprockets should be replaced when you change the chain and I am not aware of any issue with them, except the 09's use smaller bolts and some, if not all were replaced.
Wheel bearings seem to go out sooner than normal but a lot of them are on the same bikes. Woody's wheel works determined that some hubs are undersized according to the bearing specs. A good question to ask the original owner. I know some of those aflicted and they had the bores honed out with no further issues.
754 front axles were recalled and they have not all been fixed. All assembled in 08 but sold as 09's. BMW knows which vin numbers have them.
Some got cosmetically cracked tanks and some of the old stock replacement tanks cracked also. They have been redesigned and I do not think they have cracked.
The fuel gauge gets its reading off a strip of some sort, electonically. It never was meant to be that accurate until the gas was low enough due to its horseshoe shape. A lot of riders don't read the manual. BMW "fixed" it by doing away with the function. It now starts to read when the fuel light comes on. I like the old version and don't intend to let them change the software. At least it is optimistic and empty really means I have at least 25 miles left.
Fuel pumps are problematic on a lot of the European bikes and whether this one is any worse than any other, I can't say. It is in the tank to keep it cool, so not a good idea run it empty too often. It is a Bosch auto pump available on some car only sold in Europe. If you can find a source, much cheaper than what BMW sells it for.
I have had all those issues and a few more, except for the fuel pump and bearings. The chain I replaced with a DID after one look. The bearings I added some grease after picking out the seal. I check them everytime I change the tire. No fuel pump issues but I do run techron in the tank occasionally.
There must be close to 30,000 of these bikes out there and the squeaky wheel does get the Internet post. Whether the number you read is excessive or not is hard to say, but it at least puts you on guard to do some preventive maintenance.
For me it was not Internet complaints as I had the problems. It was not the problems themselves, as they were fixed under warranty. It was the manner in which BMW did it. No one had heard of such problems is the typical dealer response. BMW customer service denied having a chain issue while they were specing its replacement. I see the same approach on other issues that are "wear items," blame it on the user.
Like you, this bike is close to what I wanted and the good news is that once addressed, I have not had another problem in the past 26 mos. I have some mechanical skills and thanks to the Internet, know what to look for in the way of prevention and some cheaper solutions than ones purchased from BMW.
I do think the early buyers served as test mules and later bikes got the upgrades. Another issue I have with BMW, they do not tell anyone of the changes.
I think the 09's are as good now as the later models, as I am sure the owners took advantage of the warranty.
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