Five Suzuki Recalls for V-Strom 1000, V-Strom 650, SFV650 & Burgman

MotorcycleUSA Staff | January 8, 2016

Suzuki issued five recalls through the National Highway Traffic Safety Administration recently, concerning a number of V-Strom 1000, V-Strom 650, SFV650 and Burgman models. Below is a breakdown of the specifics of each recall. Suzuki customer service can be reached at 1-714-966-7040 for more information.

2014 Suzuki V-Strom 1000

Suzuki Recall ID Number 2A53
2014 DL1000 (V-Strom 1000) – Manufactured January 17, 2014 – June 5, 2014
2015 DL1000 (V-Strom 1000) – Manufactured November 5, 2014 – February 6, 2015

This batch comprises three of the recalls Suzuki issued through the NHTSA. The first recall addresses the potential for the ignition switch terminals to become corroded if they come into contact with liquid, such as salt water. The Defect Notice submitted to the NHTSA states that if such corrosion occurs, “the ignition lead wire and wire harness terminals of the connector can be connected, completing the power circuit independent of the ignition switch. Under this condition, the engine cannot be stopped by turning off the ignition key.” Suzuki Motor Corporation received reports of this problem occurring in the Netherlands, the United Kingdom, Austria, Japan and Canada throughout 2015.

Suzuki will install a cover on the ignition switch connector to rectify the issue. If corrosion is found to have already taken place, the ignition lead wire and wire harness will be replaced as well. The repairs will be completed free of charge, and owners that have already paid to fix the issue prior to the recall will be reimbursed.

The same selection of V-Strom 1000 motorcycles has a second recall, this one owing to the potential for the “battery ground connection (to) develop poor conductivity due to corrosion or a weak connection to the painted surface of the crankcase to which it is attached.” If the issue is present, “the engine may stall and be unable to be restarted.”

Suzuki will move the battery ground connection to an unpainted surface, near the exhaust pipe. The wire protector will be replaced as well with a high-heat resistant tube. As with the first recall, Suzuki dealers will remedy the issue free of charge and reimburse any owners that have already incurred costs in fixing the problem.

And finally the third recall for this group of V-Strom 1000s is to address a “wiring harness that may rub against the bottom of the fuel tank. Vibration from riding may cause the wiring insulation to wear off, allowing bare wire to short circuit against the fuel tank.”

Suzuki dealers will reroute wire harnesses found to be in the improper position. If wear is shown, dealers will add protective tape. If bare wire is shown, dealers will replace the entire wire harness.

2013 Suzuki V-Strom 650 ABS Comparison

Suzuki Recall ID Number 2A50, 2A51, 2A52
2013-2014 SFV650
2013-2014 AN650A (Burgman 650 ABS)
2012-2014 DL650A (V-Strom 650 ABS)

The NHTSA summarizes the issue with the three above listed models as such: “contamination from component production and storage combined with manufacturing variations may result in excessive tappet and camshaft wear within the engines of the affected motorcycles.”

The concern is that if tappet clearance becomes too large, the engine may stall, increasing the risk of a crash. Suzuki received its first field reports regarding the issue back in June 2013, but were unable to successfully diagnose the problem for more than two years. Changes to production processes and tappet material were initiated in the search for a solution, but it wasn’t until November 2015 that SMC found that contamination from the partition boards used for storage may have entered the cylinder head assemblies.

Suzuki dealers will inspect models within the recall range and if necessary replace the tappets and camshafts. Motorcycles with less than 2500 miles will have tappets and camshafts replaced regardless of tappet clearance or signs of wear. All service will be provided free of charge.

2014 Suzuki SFV650

Suzuki Recall ID Number 2A49
2013 SFV650 – Manufactured March 23, 2013 – April 8, 2013
2014 SFV650 – Manufactured October 24, 2013 – November 26, 2013
2015 SFV650 – Manufactured August 9, 2014 – September 12, 2014

According to the recall notice regarding this range of SFV650s, the fuel tank breather hose may not have been positioned properly during assembly, and may become kinked. Fuel tank pressure may become abnormally high or low and in extreme instances could deform or crack the tank. Suzuki cites a new assembly line process as the cause of the issue.

Suzuki will inspect and replace the fuel tank breather hose, and in cases where it’s found that the breather hose is obstructed, the fuel tank will be replaced as well. All service will be provided by dealers free of charge.