2003 Honda VFR800

Defect. ON CERTAIN MOTORCYCLES, THE FRONT FAIRING SUB-HARNESS (SECTION OF THE WIRING HARNESS) TRANSFERS THE ELECTRICAL GROUNDING LOAD OF THE HEADLIGHTS, FRONT TURN SIGNALS, INSTRUMENT PANEL, AND VARIOUS RELAYS TO THE MAIN WIRING HARNESS VIA AN 18-PIN CONNECTOR. UNDER CERTAIN CONDITIONS, THE GROUND WIRE TERMINALS INSIDE THE CONNECTOR CAN OVERHEAT, RESULTING IN MELTING OF THE CONNECTOR AND A LOSS OF POWER TO VARIOUS CIRCUITS.

Risk. AS A RESULT, A LOSS OF CRITICAL LIGHTING OR ENGINE POWER COULD OCCUR WITHOUT WARNING, WHICH COULD CAUSE A CRASH.

Remedy. DEALERS WILL INSTALL A RE-DESIGNED SUB-HARNESS. IF DAMAGE IS FOUND, THE MAIN WIRING HARNESS WILL ALSO BE REPLACED FREE OF CHARGE. AN INTERIM LETTER WAS MAILED TO OWNERS ON SEPTEMBER 26, 2007. OWNERS WERE RE-NOTIFIED ON NOVEMBER 10, 2007, TO TAKE THEIR MOTORCYCLES TO DEALERS TO HAVE THE PARTS INSTALLED. OWNERS MAY CONTACT HONDA AT 1-866-784-1870.

Defect. CERTAIN MOTORCYCLES EQUIPPED WITH COMBINED-BRAKE SYSTEMS HAVE A PROPORTIONING CONTROL VALVE (PCV) THAT MECHANICALLY PROPORTIONS BRAKE FORCE WHEN THE REAR BRAKE IS APPLIED. A SEAL IN SOME PCVS IS IMPROPERLY SHAPED, AND BRAKE FLUID LEAKAGE MAY OCCUR.

Risk. IF THE MOTORCYCLE CONTINUES TO BE USED AFTER A LEAK OCCURS, THE REAR BRAKE WOULD EVENTUALLY BECOME INOPERATIVE. A LOSS OF REAR BRAKE FORCE COULD INCREASE THE RISK OF A CRASH.

Remedy. DEALERS WILL INSPECT THE REAR BRAKE FORLEAKAGE. IF LEAKAGE IS CONFIRMED, THE DEALER WILL REPLACE THE PCV FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 31, 2005. OWNERS MAY CONTACT HONDA AT 866-784-1870.

MY ISSUE WAS FIRST DISCOVERED IN 2012 WHEN I COULD NOT START MY MOTORCYCLE; MY FIRST THOUGHT WAS AN OLD BATTERY. UPON RESEARCHING ON VFRDISCUSSION.COM I WAS EXPOSED TO NUMEROUS VFR OWNERS WITH STARTING ISSUES THAT WAS RELATED TO THE ELECTRICAL AND CHARGING ISSUES, A KNOWN ISSUE WITH MY 2003 MODEL YEAR. FROM THE INFORMATION GATHERED I STARTED TO INVESTIGATE MY MOTORCYCLE TO SEE IF THE ISSUE IS INDEED TRUE. I DID A SERIES OF SUGGESTED ELECTRICAL TESTING WITH A MULTIMETER AND THE RESULTS PROVE NEGATIVE. I PROCEEDED TO REMOVE THE PLASTIC COVERING TO EXPOSE WIRING TO SEE IF I HAVE BURNT CONNECTORS AND WIRING, WHICH I DO. I HAD THE ELECTRICAL SYSTEM REPAIRED WITH NEW STATOR, REGULATOR/RECTIFIER AND BATTERY. AFTER THE REPAIR I WAS ABLE TO RIDE FOR THE SEASON. MY BATTERY WAS CHARGING, ELECTRICAL SYSTEM WAS GOOD, NO ISSUES. NOW IN 2013 I AM HAVING THE SAME CHARGING ISSUE AGAIN. THE BATTERY IS NOT CHARGING, NOT ABLE TO START THE MOTORCYCLE. MY CONCERN HERE IS THAT AMERICAN HONDA IS NOT BEING PROACTIVE ABOUT THEIR PRODUCT ISSUE. THERE ARE NUMEROUS VFR800 OWNERS WITH SIMILAR ELECTRICAL ISSUES, ISSUES LIKE BURNT STATOR AND WIRING/ CONNECTORS. THIS ELECTRICAL ISSUE HAS LEFT ME STRANDED FAR FROM HOME. PLEASE ADDRESS THIS ISSUE. THANK YOU. *TR

TL*THE CONTACT OWNS A 2003 HONDA VFR800. WHILE RIDING 70 MPH, THE HEADLIGHT SHUT OFF WITHOUT WARNING. THE CONTACT BELIEVED THAT THE FRONT FAIRING SUB-HARNESS TRANSFERRED THE ELECTRICAL GROUNDING LOAD OF THE HEADLIGHT TO OTHER COMPONENTS AND CAUSED THE FAILURE. NHTSA CAMPAIGN ID NUMBER 07V359000 (ELECTRICAL SYSTEM:WIRING) WAS REFERENCED. THE DEALER HAS NOT INSPECTED THE VEHICLE. THE POWERTRAIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 27,239.

2003 HONDA VFR MOTORCYCLE SHUT OFF WHILE OPERATING AT APPROX. 30 MPH / 3500 RPM. SAFELY PULLED OFF ROAD AND PARKED. HEADLIGHTS & DASHBOARD LIGHTS DIM, BUZZING SOUND FROM DASHBOARD. BIKE RESTARTED ONLY WHEN HEADLIGHT FUSE WAS REMOVED. BIKE CURRENTLY AT HONDA DEALER FOR REPAIRS. EXTENSIVE DISCUSSION OF THIS PROBLEM, SOLUTION, AND ELECTRICAL SYSTEM DESIGN FLAWS IN NUMEROUS 6TH GENERATION (2002 - 2007) VFRS AVAILABLE AT "HTTP://WWW.VFRDISCUSSION.COM/FORUM/INDEX.PHP?SHOWFORUM=2" (1ST THREAD). SOLUTIONS INCLUDE ADDITIONAL ELECTRICAL GROUNDS, HEAVIER GAUGE WIRING &/OR HEAVIER DUTY FUSE HOLDERS. THIS IS A LIFE THREATENING DESIGN FLAW! IF THE BIKE WERE TO SHUT DOWN AT HIGH SPEED, IN HEAVY TRAFFIC, UNDER DEMANDING ROAD CONDITIONS, ETC, A SEVERE CRASH WOULD BE VERY LIKELY. PLEASE ENCOURAGE HONDA TO ISSUE A RECALL TO CORRECT THIS PROBLEM IMMEDIATELY. *TR

REGARDING INVESTIGATION PE05047 THIS INVESTIGATION WAS CLOSED 12/20/05, BUT I HAVE READ MANY COMPLAINTS FROM OWNERS OF THIS MODEL THAT ARE HAVING THE SAME PROBLEM. MY HONDA VFR800 SHOWS SIGNS OF FAILURE DURING NORMAL USE AND THERE ARE NO "MODIFICATIONS TO THE WIRING HARNESS" AS SUGGESTED BY YOUR INVESTIGATION. THE ONLY AUXILIARY LOADS I HAVE ON MY BIKE ARE CONNECTED BY SEPARATE HARNESS DIRECTLY TO THE BATTERY AND THEREFORE BYPASS THE MAIN WIRING HARNESS. YET A CABLE, FUSE BLOCK AND A CONNECTOR ON THE FACTORY HARNESS DIRECTLY ATTACHED TO THE BATTERY GET HOT TO THE TOUCH IN NORMAL USE. SEVERAL OWNERS HAVE REPORTED THAT THEY HAD TO MAKE SEVERAL ATTEMPTS AT HAVING THE HONDA DEALERS ADMIT TO THE PROBLEM, AND THAT THE FACTORY NEVER DID, YET AFTER SUFFICIENT COMPLAINTS REPLACED THE ENTIRE WIRING HARNESS WITH AN UPGRADED MODEL. I WOULD THINK THAT THIS KIND OF FAILURE (MELTED WIRING INSULATION, BURNT FUSE BLOCK, MELTED CONNECTORS) WOULD CONSTITUTE A SAFETY HAZARD AND THAT NHTSA AND HONDA WOULD WANT TO RESOLVE THIS MORE PROACTIVELY. *NM

DT: THE CONTACT STATED THE ELECTRICAL SYSTEM BURNED. THIS CAUSED THE HEADLIGHTS NOT TO WORK. THE CONTACT NOTICED THE PROBLEM WHEN HE PURCHASED THE VEHICLE, AND TOOK IT TO A LOCAL DEALERSHIP, WHO HAD THE ELECTRICAL SYSTEM REPLACED UNDER WARRANTY. THE DEALERSHIP STATED IT WAS BECAUSE OF THE PREVIOUS OWNER'S NEGLIGENCE. *AK

DT: THE CONSUMER EXPERIENCED AN ELECTRICAL PROBLEM, THERE IS A BUZZING NOISE COMING FROM THE FRONT OF VEHICLE, ONE OF THE WIRES COMING FROM THE BATTERY BECAME HOT, CAUSING IT TO MELT. THE FUEL PUMP DOES NOT WORK, CAUSING VEHICLE NOT START, VEHICLE SHUTS OFF AT HIGHER SPEEDS, CONSUMER TOOK VEHICLE TO DEALER, WHO TRIED TO FIX PROBLEM, BUT PROBLEM RECURRED. *AK *SC *JB

MOTORCYCLE HEADLIGHTS INTERMEITTENTLY TURN OFF. ELECTRICAL PROBLEM ALSO RESULTING IN MOTORCYCLE TURNING OFF DURING OPERATION. REFERE TO THIS WEB SITE FOR MANY DETAILS: HTTP://WWW.VFRDISCUSSION.COM/FORUM/INDEX.PHP?SHOWTOPIC=6856&HL=MY+FIRST+ELECTRICAL+PROBLEM

MOTORCYLE ENGINE WOULD TURN OVER, START, AND RUN STRONG, BUT WOULD DIE AFTER THE STARTER BUTTON WAS RELEASED. LOOKING OVER INTERNET DISCUSSION FORUMS THAT ARE DEDICATED TO THIS MODEL MOTORCYCLE, 2002-2005 HONDA VFR800, REVEALED A SUBSTANSIAL*AK NUMBER OF OWNERS EXPERIANCED THE SAME PROBLEM, MOST OF THE OWNERS ARE IN WET CLIMATES, EG., SEATTLE, PORTLAND, BRITISH COLUMBIA, ETC. FOLLOWING THE TROUBLE SHOOTING METHODS RECOMMENDED ONE THE DISCUSSION FORUM (REMOVED THE HEADLIGHT FUSE AND THE BIKE WOULD START AND RUN FINE UNTIL EITHER THE FUSE WAS REPLACED OR THE TURN SIGNALS WERE ACTIVATED) THE PROBLEM WAS TRACED TO THE GROUND WIRE FOR THE FORWARD PORTION OF THE MOTORCYCLE. THIS WIRE COVERS THE HEADLIGHTS, INGINTION, INSTRUMENTS, ETC. THE PIN FOR THIS WIRE INSIDE THE MAIN WIRING CONNECTOR BLOCK HAD CORRODED AND GOTTEN HOT AS EVIDENCED BY MELTING OF THE CONNECTOR BLOCK AROUND THE PIN. THE OTHER 23 PINS IN THE CONNECTOR BLOCK WERE SHINY, CLEAN, AND APPEARED NEW. IF THIS FAILURE WERE TO OCCUR DURING OPPERATION, THE MOTORCYCLE WOULD STALL, AND THE HEADLIGHTS WOULD GO OUT, AT NIGHT THIS COULD CAUSE THE RIDER TO LOSE CONTROL AS HE/SHE COULDN'T SEE THE THE ROAD OR ANY HAZARDS, NOR COULD OTHER MOTORISTS SEE THE MOTORCYCLE.