2004 SUZUKI SV650S Recalls, Complaints & Safety

EQUIPMENT

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.

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.

10,000 vehicles affected

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

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.

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.

4,841 vehicles affected

I HAVE A 2004 SV650S I HAVE FOUND THAT WHEN RIDING IN THE RAIN THERE BECOMES WATER BECOMES TAPED IN THE FRONT CYLINDERS SPARK PLUG BOOT AREA AND CAUSES THE ENGINE TO RUN ON ONE CYLINDER. I SEE THE SAFETY PROBLEM BECAUSE IT CAN SURGE A LOT OF POWER WHEN THE CYLINDER IS INTERMITTENTLY FIRING. IF THE FENDER WAS EXTENDED OR A BETTER SEALING SPARK PLUG WAS INSTALLED IT WOULD BE MOST LIKELY REMEDIED. SINCE DOING SOME RESEARCH I FIND THIS IS A PROBLEM MANY OTHER SV650 MAY HAVE AS WELL. *TR

THE VEHICLE IN QUESTION IS A 2004 SUZUKI SV650S MOTORCYCLE, WITH APPROXIMATELY 21,000 MILES ON THE ODOMETER. THE PROBLEM IS A WIRING CONNECTION FROM THE IGNITION SWITCH TO THE MAIN WIRING HARNESS. THE PLUG-IN STYLE CONNECTOR HAD ONE OF ITS PINS SHORT OUT AND MELT THE SURROUNDING PLASTIC, CAUSING A VERY UNRELIABLE CONNECTION. I HAVE NOT SO MUCH AS TOUCHED THIS CONNECTOR BEFORE THIS INCIDENT. ONCE THIS HAS SHORTED, THE ELECTRICAL CONNECTION IS PRONE TO DROPPING OUT INTERMITTENTLY AND UNPREDICTABLY. SINCE THIS IS CONNECTED WITH THE MAIN IGNITION SWITCH, WHEN THIS CONNECTION IS LOST ALL ELECTRICAL POWER TO THE MOTORCYCLE SHUTS OFF. A MOTORCYCLE IN A CORNER, OR IN TRAFFIC WITH A DEAD ELECTRICAL SYSTEM (AND THEREFORE NO MOTOR) IS AN EXTREMELY DANGEROUS SITUATION! THIS PROBLEM IS WELL KNOWN AMONGST ONLINE COMMUNITIES FOR THIS MOTORCYCLE (SUZUKI SV650 AND SV1000), AND HAS CAUSED SEVERAL RIDERS TO CRASH. THE PROBLEMS IS DUE TO A DESIGN FLAW WITH THE CONNECTOR- THE CONNECTING PINS ARE UNABLE TO HANDLE THE CURRENT FROM THE MAIN IGNITION LOOP AND ARE PRONE TO OVERHEATING. I USED AN AFTERMARKET CONNECTOR WITH THE ORIGINAL WIRES, CAPABLE OF HANDLING MORE CURRENT RELIABLY, AND HAVE NOT SEEN THE PROBLEM REPEAT ITSELF. *TR