2009 SUZUKI VL800 Recalls, Complaints & Safety

ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

SUZUKI IS RECALLING CERTAIN MODEL YEAR 2008 THROUGH 2010 MOTORCYCLES MANUFACTURED FROM JULY 2007 THROUGH SEPTEMBER 2009, EQUIPPED WITH REGULATOR/RECTIFIER ASSEMBLIES, SUZUKI PART NUMBERS 32800-41F11, 32800-15H10, 32800-05H11, 32800-41G10, 32800-15H00, 32800-18H00, 32800-05G10, 32800-10G10, 32800-05H20, OR 32800-06G01. SOME REGULATOR/RECTIFIER ASSEMBLIES WERE PRODUCED WITH INSUFFICIENT ADHESION BETWEEN THE POWER MODULE (CIRCUIT BOARD) AND THE RECTIFIER CASE THAT CONTAINS A HEAT SINK TO DISSIPATE HEAT. DUE TO INSUFFICIENT ADHESION, HEAT GENERATED ON THE POWER MODULE CIRCUIT BOARD CAN CAUSE THE CIRCUIT BOARD TO DEFORM, AND LIFT OF THE CASE.

Remedy: SUZUKI WILL NOTIFY OWNERS AND SUZUKI DISTRIBUTORS WILL REPLACE THE REGULATOR/RECTIFIER WITH AN IMPROVED PART FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MARCH 2, 2011. OWNERS MAY CONTACT SUZUKI AT 1-714-572-1490.

73,426 vehicles affected

MAKING A DOWNSHIFT FROM 3RD TO 2ND AROUND A CORNER I APPLIED THROTTLE THEN A BIG CLUNK OCCURRED AND I LOST POWER TO MY REAR DRIVE. I WAS ABLE TO MAKE IT TO THE SIDE OF THE ROAD, ELUDING TRAFFIC TO MOVE TO THE RIGHT LANE. UPON INVESTIGATION I'VE FOUND OUT THE PROBLEM TO BE THE FINAL DRIVE PROPELLER GEAR AND THE COUPLING WERE RUSTED AND TOTALLY WORN OUT. THIS JOINT HAD NEVER BEEN LUBED DURING ORIGINAL MANUFACTURING ASSEMBLY. THIS LACK OF LUBE HAS CAUSED THE SHAFT TO RUST CAUSING THE FAILURE. THE GREASE CANNOT BE APPLIED UNLESS THE FINAL DRIVE IS TOTALLY REMOVED. THIS IS A KNOWN PROBLEM WITH THE 05-09 MODEL YEARS AS EVIDENCE BY A SIMPLE INTERNET SEARCH. NO RECALL HAS BEEN ISSUED YET. THE COST OF THE CHANGE IS AROUND $600 - $800 DOLLARS BUT THIS DEFFECT CAN CERTAINLY CAUSE AN ACCIDENT FOR THE LOSS OF POWER WHILE OPERATING THE MOTORCYCLE ON THE HIGHWAY.

COMING AROUND A CORNER UP A HILL I APPLIED THROTTLE TO GO UP HILL. A LARGE CLUNK OCCURRED AND I LOST ALL FORWARD ABILITY. NOT HAVING POWER I BARELY MADE IT TO THE SIDE OF THE ROAD ALMOST GETTING HIT. I SWERVED TO AVOID A CAR AND WENT DOWN. NOTHING OTHER THAN MINOR SCRAPES AS A RESULT. UPON DETERMINING THE PROBLEM TO BE THE FINAL DRIVE I REMOVED THE PART AND FOUND IT WAS NEVER LUBED DURING ASSEMBLY. THIS CAUSED THE SHAFT TO RUST CAUSING THE FAILURE. THERE IS NO WAY TO APPLY GREASE TO THE PART WITHOUT ENTERING THE NON MAINTENANCE AREA OF THE FINAL DRIVE. THIS IS A KNOWN PROBLEM WITH THE 05-09 MODEL YEARS AS EVIDENCE BY A SIMPLE INTERNET SEARCH. NO RECALL HAS BEEN ISSUED YET. I WAS LUCKY AND MADE IT OUT OF TRAFFIC, OTHERS MAY NOT BE AS LUCKY. *TR

Crash

2009 SUZUKI VL800TK9. CONSUMER WRITES IN REGARDS TO REPAIR REIMBURSEMENT AND RECALL *TGW THE CONSUMER STATED SHE RETURNED THE BIKE TO THE DEALER, BECAUSE THE SPEEDOMETER WAS OFF BY 9 MPH. THE DEALER REPLACED THE COMPONENT, BUT IT DIDN'T CORRECT THE PROBLEM. THE CONSUMER WAS INFORMED THERE WASN'T ANYTHING ELSE THAT COULD BE DONE AND IT WAS PROBABLY A MANUFACTURING DEFECT. *JB

RECEIVED RECALL NOTICE FROM AMERICAN SUZUKI CORPORATION. MOTOR CYCLE TAKEN TO DEALERSHIP, IT HAS BEEN THERE A MONTH. I HAVE CHECKED EVERY WEEK. I AM TOLD THEY HAVE GOTTEN NO RESPONSE ABOUT A REPLACEMENT PART. CAN YOU HELP RESOLVE THIS MATTER IN A TIMELY FASHION? COMPONENT THAT NEEDS TO BE REPLACED: RECTIFIER ASSEMBLIES INSTALLED ON THE AFFECTED MODELS MAY HAVE A CONDITION WHICH CAN CAUSE THE INTERNAL CIRCUIT BOARD TO FAIL IN SERVICE DUE TO EXCESSIVE HEAT.