2003 Suzuki SV1000S

Defect. MOTION PRO IS RECALLING 10,000 AFTERMARKET BRAKE LEVERS, MODEL NO. 14-0415, SOLD FOR USE ON CERTAIN MY 1999 THROUGH 2008 SUZUKI AND MY 1998 THROUGH 2003 YAMAHA MOTORCYCLES. THE LOBE HEIGHT ON SOME OF THESE LEVERS ARE SMALLER AND DO NOT PROPERLY ENGAGE THE STOMP LAMP SWITCH WHICH WILL NOT DEACTIVATE WHEN THE DRIVER RELEASES THE BRAKE LEVER. THE LEVER CAN BE IDENTIFIED BY THE MARKING "JY 378" AT THE BASE OF THE LEVER NEAR THE PIVOT BUSHING.

Risk. IF THIS OCCURS, THE STOP LAMP WILL REMAIN ON WHICH COULD POSSIBLY RESULT IN A CRASH.

Remedy. MOTION PRO WILL NOTIFY OWNERS AND PROVIDE A FREE REMEDY. THE RECALL BEGAN ON SEPTEMBER 11, 2008. OWNERS MAY CONTACT MOTION PRO AT 1-877-438-7831.

Defect. ON CERTAIN CALIFORNIA-SPECIFICATION MODEL MOTORCYCLES, REPEATED STRESS FROM VIBRATION CAN CAUSE A CRACK TO FORM IN THE AREA WHERE THE LIQUID/VAPOR SEPARATOR BRACKET IS WELDED INSIDE THE FUEL TANK. THIS CAN ALLOW FUEL LEAKAGE TO OCCUR.

Risk. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.

Remedy. DEALERS WILL REPLACE THE FUEL TANK FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 3, 2006. CUSTOMERS MAY CONTACT AMERICAN SUZUKI AT 714-572-1490.

MOTORCYCLE WOULD NOT CHARGE BATTERY AND COMPLETELY DIED BECAUSE OF IT ONE DAY. OPENED UP MAGNETO COVER AND FOUND THE ROTOR MAGNETS HAD DISINTEGRATED. RUINED THE ROTOR AND MAGNETO AND ONLY HAD 17,000 MILES ON IT. CLEANING UP BITS OF MAGNET ALL AROUND THE CRANK AND INSIDE THE ENGINE.

IN MID RIDE I WAS APPROACHING A LOW SPEED CORNER AT THE END OF A HIGH SPEED STRAIGHT AWAY. I TRIED TO PULL MY CLUTCH HANDLE IN TO BEGIN TO BRAKE AND DOWNSHIFT AND THE CLUTCH HANDLE HAD NO RESISTANCE AT ALL. COMPLETE FAILURE OF THE HYDRAULIC CLUTCH SYSTEM. UNABLE TO TAKE THE DRIVE PRESSURE OFF THE REAR TIRE THE BIKE LOST TRACTION IN THE REAR AND LOWSIDED THE BIKE INTO A 6 FOOT DITCH AT AROUND 60 TO 70 MPH. I RECEIVED MINOR INJURIES THANKS TO MY GEAR BUT INJURIES NONE THE LESS. I HAVE SPOKEN TO MANY MOTORCYCLE MECHANICS AND ALL OF THEM HAVE STATED THAT HYDRO CLUTCHES ARE DEATH TRAPS. AND ALMOST ALL OF THEM SAID TO GET A CABLE CLUTCH CONVERSION KIT ASAP. NO I KNOW WHY. THIS IS A RESULT OF SUZUKI MOTORS OUTSOURCING THEIR WORK TO CHEAP LABOR AND NOT CHECKING TO MAKE SURE THEIR PARTS ARE WITHIN THE TOLERANCES THAT WERE SET FOR THAT PART. I STRONGLY BELIEVE THAT SUZUKI NEEDS TO SUSPEND PRODUCTION ON ALL SV1000 BIKES AND ISSUE A RECALL TO FIX ALL THE PARTS THAT HAVE BEEN POORLY MADE WITH UNSAFE RESULTS. THE FLYWHEEL ROTORS LOSE THE MAGNETS ON ALMOST EVERY 2003 SV1000 AND ITS BEGINNING TO EFFECT UP TO THE 05 MODELS. I AM ON 2 DIFFERENT FORUMS FOR THIS BIKE THAT ARE INTERNATIONAL FORUMS THE FLYWHEEL MAGNETS ARE THE SECOND MOST COMMON FAILURE FROM SUZUKI JUST BEHIND THE PISS POOR JOB ON THE CLUTCH BASKET HUB BEARING. NOW THE FUEL TANKS ARE KNOWN TO RANDOMLY BURST INTO FLAMES WHEN THE FUEL LINE LEAKS UNDER THE TANK. THIS BIKE SHOULD BE REMOVED FROM MARKET UNTIL SUZUKI CAN GET IT RIGHT. T

MY SUZUKI SV1000S HAS AN ELECTRICAL PROBLEM. I FIRST NOTICED THIS PROBLEM WHEN I ATTEMPTED TO START THE MOTORCYCLE IN MY GARAGE IN MAY OF 2011. I TURNED THE SWITCH AND NOTHING CAME ON. I CHECKED THE BATTERY AND THERE WAS NO PROBLEM WITH IT. MYSTERIOUSLY, THE ELECTRICAL SYSTEM STARTED WORKING SEVERAL DAYS LATER. THIS HAS HAPPENED ABOUT 3 TIMES. ON 09/26/2011, I WAS RIDING WITH MY 12-YEAR-OLD DAUGHTER ON A BUSY 2-LANE ROAD. IT WAS A BEAUTIFUL EVENING (5 PM, SUNNY, ABOUT 85 DEGREES). WE WERE APPROACHING A STOP SIGNAL (SPEED APPROXIMATELY 20 MPH). THE CLUTCH WAS ENGAGED AND I WAS LIGHTLY APPLYING FRONT AND REAR BRAKES. THE MOTORCYCLE LOST ALL ELECTRICAL POWER WHILE WE WERE STILL MOVING. AFTER A FEW MOMENTS, THE POWER WAS RESTORED AS MYSTERIOUSLY AS IT LEFT. PLEASE CHECK INTO THIS AS THERE HAS BEEN NUMEROUS COMPLAINTS ABOUT THIS TYPE OF INCIDENT POSTED ONLINE. THIS COULD HAVE CAUSED A SERIOUS ACCIDENT RESULTING IN INJURY OR THE LOSS OF LIFE. *TR

TL* THE CONTACT OWNS A 2003 SUZUKI SV1000S MOTORCYCLE. THE CONTACT STATED THAT FUEL WAS LEAKING ONTO THE MOTOR AND OVERFLOWING INTO THE CHARCOAL CANISTER. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP WHERE IT WAS DIAGNOSED THAT THERE WAS A CRACK ON THE LIQUID SEPARATOR BRACKET INSIDE THE FUEL TANK AND UNDERNEATH, THE SEAMS WERE SEPARATED. AS A RESULT, THE FUEL TANK NEEDED TO BE REPLACED. THE DEFECTIVE FUEL TANK WAS SENT TO THE DEALER TO BE INSPECTED WHO CONFIRMED DIAGNOSIS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE MOTORCYCLE HAD BEEN PREVIOUSLY REPAIRED UNDER NHTSA CAMPAIGN ID NUMBER: 06V013000 ( FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY). THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 16,071 AND THE CURRENT MILEAGE WAS 16,245.

TOTAL LOSS OF ELECTRICAL POWER DUE TO A FAULTY CONNECTION BETWEEN THE IGNITION SWITCH TO THE MAIN IGNITION RELAY. THIS RESULTS IN LOSS OF LIGHTS, INSTRUMENTS, AND IGNITION POWER. THE ENGINE STALLS AND CAN EASILY CAUSE AN ACCIDENT AND INJURIES. *TR

CONNECTOR FROM THE IGNITION SWITCH TO WIRING HARNESS OVERHEATED AND THE CONNECTOR NO LONGER HELP THE WIRES TOGETHER FOR THE IGNITION. TURN THE KEY - NO POWER AT ALL TO THE BIKE. I HAVE READ ABOUT DOZENS OF RIDERS THIS HAS HAPPENED TO, SOME HAVE HAD ACCIDENTS AS A RESULT. LUCKILY I WASN'T IN MOTION WHEN THE POWER GAVE OUT. *TR

2003 SUZUKI SV1000, WILL NOT START, NO ELECTRIC AT ALL. MUST TAKE OFF SEAT & MOVE WIRES, THEN WILL START, IT DOES THIS EVERY TIME I TURN IT OFF. HAVE READ MANY POSTS ABOUT THE "GREEN CONNECTOR" MANY OTHERS HAVING THE SAME PROBLEM. *TR

ELECTRICAL HARNESS ON MY BIKE (SV1000S 2003) WENT BAD AND NO POWER IS GOING TO ANYTHING. *TR

MY SUZUKI SV 1000S 2003 # HAS A FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE WHICH CAN RESULT IN FIRE. I FOUND OUT ON THE SUZUKI WEBSITE THAT THERE IS A RECALL FOR THIS KIND OF PROBLEM. I CONTACTED SUZUKI AND THEY SAID THE RECALL IS ONLY FOR CALIFORNIA MODELS AND MY BIKE IS NOT ONE OF THOSE. I TOOK THE MOTORCYCLE TO AN AUTHORIZED DEALERSHIP AND THEY SAID THE CAUSE OF THE LEAK IS A CRACK IN THE AREA WHERE THE LIQUID/ VAPOR SEPARATOR BRACKET IS WELDED INSIDE THE TANK AND THE SOLUTION FOR THE PROBLEM WOULD BE A TANK FUEL REPLACEMENT, JUST LIKE IT SAYS ON RECALL ID# 32059 RECALL DATE JAN/18/06. MY QUESTION IS, IF THE PROBLEM ON MY BIKE IS EXACTLY THE SAME WHY MY MOTORCYCLE IS NOT INCLUDED IN THE SAME RECALL? THANKS ! WES MORAES. *TR

2003 SV1000S LOST ALL ELECTRICAL POWER DUE TO A FAULTY GREEN IGNITION CONNECTOR LOCATED IN FRONT OF THE AIRBOX. THE GREEN CONNECTOR MELTED AT THE POSITIVE WIRE CAUSING LOSS OF ELECTRICAL POWER. HARD WIRED IT WITH SOLDER AND SHRINK TUBING SINCE I DON'T PLAN ON REMOVING THE IGNITION ANY TIME SOON. *TR

FOR THE SECOND TIME, THE GREEN CONNECTOR CONNECTING THE IGNITION TO THE WIRING HARNESS HAS FAULTED, PREVENTING THE MOTORCYCLE FROM RUNNING. LET ME REPEAT, THE SECOND TIME. I HAD THE IGNITION REPLACED, AND TWO MONTHS LATER IT HAPPENED AGAIN. *TR

TL*THE CONTACT OWNS A 2003 SUZUKI SV1000S. WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE LOST POWER AND BEGAN TO DECELERATE. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE AND HE DISCOVERED THAT THE GREEN POWER CONNECTOR FUSED TOGETHER, CAUSING AN ELECTRICAL SHORT. THE GREEN POWER CONNECTOR WAS REPLACED, BUT THE FAILURE RECURRED. THE VEHICLE HAS NOT BEEN TAKEN TO A DEALER FOR DIAGNOSIS. THE CURRENT MILEAGE WAS 9,500 AND FAILURE MILEAGE WAS 9,000.

I HAVE A SUZUKI SV1000S E-33 (CA VERSION) FROM THE YEAR 2003. THIS MODEL BIKE HAD A FACTORY RECALL FOR DEFECTIVE FUEL TANK. THE DEFECT WAS THAT DUE TO VIBRATION THE FUEL VAPOR SEPARATOR WELD INSIDE THE FUEL TANK WOULD CRACK, AND FUEL WOULD LEAK TO THE CHARCOAL CANISTER, CAUSING IT TO FLOOD AND DRIP FUEL. THIS REPRESENTS A FIRE HAZARD SINCE IT IS LOCATED RIGHT ABOVE THE EXHAUST. I TOOK MY BIKE TO A SUZUKI DEALER TO HAVE THE DEFECT CORRECTED BECAUSE OF THE RECALL. THE BIKE NOW, WITH ITS NEW, AND IN THEORY IMPROVED, FUEL TANK IS HAVING THAT EXACT PROBLEM. WHEN THE FUEL TANK IS FULL, FUEL LEAKS OUT TO THE CANISTER AND ON TO THE EXHAUST. ALSO, ENGINE RUNS VERY RICH, AND EXCESS FUEL IN THE CYLINDERS MIGHT EVEN GET THE ENGINE TO STUCK. THIS EXCESS FUEL FIND ITS WAY TO THE EXHAUST MANIFOLD AND WHEN THE ENGINE STARTS THIS TUBES GETS SO HOT THAT THEY START SMOKING AND MIGHT CAUSE THE BELLY COVER TO BURN. THERE IS ABUNDANT EVIDENCE THAT THIS IS NOT JUST AN ISOLATED FAILURE: I HAVE FOUND NUMEROUS PEOPLE WITH SAME BIKE AND EXACT SAME PROBLEM. I HAVE A RECALL LETTER FROM SUZUKI EXPRESSING THAT THIS WAS IN FACT A DEFECT ON THE BIKE'S DESIGN, BUT SUZUKI MAY NOT KNOW THAT IT IS STILL A DEFECT IN THE NEW VERSION OF THE FUEL TANK. I HAVE CONTACTED A LOCAL DEALER AND THEY TOLD ME TO BRING THE BIKE IN TO GET IT CHECKED. I WILL ALSO INFORM SUZUKI OF AMERICA DUE TO THE DANGER THAT THIS DEFECT REPRESENT TO ME AND ANY OTHER SUZUKI SV1000S RIDER. *TR

HTTP://WWW.SV-PORTAL.COM/FORUMS/SHOWTHREAD.PHP?T=27074 NO ELECTRICAL POWER?? GREEN CONNECTOR ISSUE! MY BIKE LOST POWER AND CANNOT BE STARTED. FORTUNATELY I WAS NOT RIDING AT THE TIME THE POWER CUT OUT. I HAD TO FIND ANOTHER RIDE HOME AS THE BIKE WAS IMMOBILE. APPARENTLY THIS DOES OCCUR REGULARLY AND BOTH NHTSA AND SUZUKI ARE AWARE OF THE PROBLEM AND DOING NOTHING ABOUT IT. READ THE FORUM ABOVE FOR MANY INSTANCES OF THIS PROBLEM. *TR

TL*THE CONTACT OWNS A 2003 SUZUKI SV1000S MOTORCYCLE. ON TWO SEPARATE OCCASIONS, THE VEHICLE COMPLETELY SHUT OFF WITHOUT WARNING. THE VEHICLE WOULD NOT RESTART AND HAD TO BE TOWED BOTH TIMES. THE DEALER STATED THAT THE IGNITION HARNESS WAS FAULTY AND REPLACED IT TWICE. THE SPEED WAS UNKNOWN. THE CURRENT MILEAGE WAS 27,000 AND FAILURE MILEAGE WAS 23,000.

THE GREEN CONNECTOR ON THE SUZUKI SV1000S MOTORCYCLE BURNED OUT, CAUSING THE MOTORCYCLE ENGINE TO DIE COMPLETELY ON A HIGH TRAFFIC STREET. PRIOR TO THE COMPLETE FAILURE OF THE CONNECTOR THE MOTORCYCLE WOULD INTERMITTENTLY DIE FOR A FEW SECONDS, AND EITHER RESUME NORMALLY IF IN TRANSIT OR DIE IF IT WAS STATIONARY. WHEN THE ENGINE DIED ALL ELECTRICAL FUNCTIONS CEASED EVEN IF THE KEY WAS IN ACCESS MODE. TURNING THE KEY SEVERAL TIMES FROM OFF TO ACCESS WOULD RESUME THE ELECTRICAL FUNCTIONS. AFTER FINDING A BULLETIN BOARD THREAD ON THE MOTORCYCLE'S SYMPTOMS, THIS LEAD ME TO THE GREEN CONNECTOR"FAILURE. I DISASSEMBLED THE MOTORCYCLE AND LOCATED THE CONNECTOR. SURE ENOUGH, THE CONNECTOR WAS FRIED . REMOVED THE DAMAGED CONNECTOR AND REPLACED THEM WITH SPADE TERMINALS. SO FAR, THE MOTORCYCLE WORKED FINE.*AK CHECK THIS URL FOR MORE INFORMATION AND PHOTOS. MY POSTS ARE TOWARDS THE BOTTOM UNDER THE NAME "RXSX": HTTP://WWW.SV-PORTAL.COM/FORUMS/SHOWTHREAD.PHP?T=20730&PAGE=17

DT*: THE CONTACT STATED WHILE DRIVING 60 MPH, THE REAR WHEEL WOBBLED. THE TIRE PRESSURE WAS CHECKED, WHICH WAS NORMAL. THE VEHICLE SPEED WAS LOWERED TO 10 MPH, AND THE SAME THING OCCURRED 2 TENTHS OF A MILE LATER. THE REAR WHEEL AND AXLE WERE THEN TAKEN TO A SERVICE DEALER, WHO DETERMINED THAT THE RIGHT REAR BEARING HAD BEEN DESTROYED DUE TO LACK OF LUBRICATION. THE REMAINING BEARINGS WERE ALSO INSPECTED, AND WERE FOUND TO HAVE THE SAME LACK OF LUBRICATION. THE MANUFACTURER WAS ALSO NOTIFIED. THE CONTACT EXPRESSED CONCERN THAT THERE WAS NOTHING IN THE OWNERS MANUAL ABOUT HOW OR WHEN TO LUBRICATE THE BEARINGS.*AK

MY BIKE WAS HAVING INTERMITTENT ELECTRICAL STARTING PROBLEMS FOR APPROX. 2 MONTHS. THE DEALER FOUND A GREEN CONNECTOR IN THE WIRING HARNESS THAT HAD SHORTED OUT. I HAVE SINCE FOUND OUT THAT THIS IS VERY COMMON ON SUZUKI MOTORCYCLES. MY BIKE IS A 2003 SV1000S WITH 16K MILES. *NM

DT*: THE CONTACT STATED THERE WAS A STRONG SMELL OF GASOLINE ALL AROUND THE MOTORCYCLE. THE SMELL WAS PRESENT SINCE PURCHASING THE MOTORCYCLE. THERE WAS A NHTSA RECALL, #06V013000 ON THE MOTORCYCLE REGARDING THE FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY. THE PARTS NEEDED TO REPAIR THE VEHICLE WERE NOT AVAILABLE AT THE LOCAL DEALERSHIP. THE MANUFACTURER CONFIRMED THE PARTS WERE ON BACKORDER. THE CONTACT RECEIVED TWO SEPARATE RECALL LETTERS REGARDING THIS DEFECT IN JANUARY 2006. THE DEALERSHIP STILL HAS NOT REPLACED THE TANK, BECAUSE THE PARTS ARE NOT AVAILABLE. UPDATED 10/11/06. *JB

MY 2003 SUZUKI SV1000S MOTORCYCLE HAD AN INTERMITTENT TOTAL POWER(ELECTRICAL) FAILURE THAT WOULD RESULT IN THE BIKE SHUTTING OFF. I TOOK THE BIKE TO A DEALER AND THEY COULD NOT DUPLICATE THE PROBLEM. THE WEEK OF AUGUST 13-19 IT BEGAN TO GET WORSE SO I STOPPED RIDING AND BEGAN TO RESEARCH ON MY OWN AND FOUND THE IGNITION SWITCH CONNECTOR HAD FAILED AND BEGAN TO BURN THE WIRES ON THE SWITCH END. FOR RIGHT NOW THE SWITCH IS REMOVED AND NOT INSTALLED ON THE BIKE FOR FEAR OF A FIRE. THE WIRING HARNESS END HAS SOME DAMAGE BUT NOT MUCH, BUT WHEN THE CONNECTOR FAILED THE HEAT FUSED THEM TOGETHER AND GETTING THEM APART HAD VERY DIFFICULT WITHOUT CAUSING DAMAGE TO THE WIRING HARNESS END. AS OF RIGHT NOW I HAVE NOT REPLACED ANY PARTS THE BIKE IS DOWN UNTIL I CAN PURCHASE A NEW SWITCH SINCE ITS NOT UNDER WARRANTY. *JB