2006 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 STARTED TO VIBRATE MORE AT HANDLE BARS AND BECAME UNCOMFORTABLE TO RIDE. ELECTRICAL OUTPUT FROM THE MAGNETO WAS ALSO STARTING TO DROP IN DC OUTPUT. SELF INVESTIGATION INTO ISSUE REVEALED THAT THE INTERNAL MAGNETO ROTOR THAT NORMALLY HAS 6 MAGNETS EPOXIED TO IT, NOW ONLY HAD 5 EPOXIED IN THE CORRECT PLACE. THE OTHER 1 HAD BROKEN THE BOND AND WERE SLIDING AROUND CAUSING DAMAGE AND WERE ALL BUNCHED UP CAUSING THE VIBRATION ISSUE ALONG WITH THE LOW VOLTAGE OUTPUT TO THE ELECTRICAL SYSTEM. ENGINE WAS CLEANED OUT, AND PART REPLACED WITH NEW SUZUKI OEM PART. *TR

LOUD ABNORMAL KNOCKING SOUND COMING FROM ENGINE WITH CLUTCH LEVER RELEASED. SAME SOUND NEARLY INAUDIBLE WITH CLUTCH LEVER PULLED IN. PRIMARY DRIVE NUT ON CRANKSHAFT THAT SECURES PRIMARY DRIVE GEAR ASSEMBLY LOOSENED AND PARTIALLY UNTHREADED. NUT THEN MAKES WITH CONTACT WITH THE INNER RIGHT HAND ENGINE CASE AND RUBS. THE PRIMARY DRIVE GEAR IS THEN ALLOWED TO SLIDE ON THE CRANKSHAFT OUTWARDS TOWARDS THE CLUTCH ASSEMBLY AND MAKES CONTACT, THE PRIMARY DRIVE GEAR SPRING WASHER IS THEN BROKEN ALLOWING THE PRIMARY DRIVE GEAR ASSEMBLY TO SEPERATE AND LET THE INTERNAL SPRINGS FALL OUT. VARIOUS PIECES OF METAL FRAGMENTS CAN FALL INTO THE OIL SUMP. POSSIBILITY OF CLUTCH DRIVEN GEAR DAMAGE AS WELL AS CAMSHAFT DRIVE GEAR DAMAGE OR ENGINE FAILURE IF LEFT UNCHECKED. PRIMARY DRIVE GEAR SPRINGS AND SPRING WASHERS REPLACED. PRIMARY DRIVE GEAR ASSEMBLY NUT TORQUED TO SPECIFICATION. REMOVE BROKEN PARTS FROM OIL SUMP IF PRESENT. REPLACE CRANKCASE COVER GASKET, ENGINE OIL, AND COOLANT.

I PUT 500 MILES ON MY BIKE OF VERY EASY RIDING THE ENGINE ISN'T BROKEN IN UNTIL 600 MILES AND I PULLED UP TO A STOP LIGHT AND AND THERE WAS A KNOCKING GRINDING NOISE WITH THE CLUTCH OUT AND IT WENT AWAY WHEN I PULLED IT IN. I BROUGHT IT TO THE DEALER AND THEY FOUND THAT THE PRIMARY GEAR NUT HAD BACKED OFF THE CRANKSHAFT AND WAS RUBBING UP AGAINST THE ENGINE CASE. THEY PUT RED LOCTITE ON THE NUT AND RETRORQUED IT AND IT NEEDED A NEW CASE GASKET. THE BIKE IS A 2006 SV1000S. *NM