2A67 – Stator Assv Replacement – 2012-2016 Suzuki DL650

NHTSA Campaign Number: 16V878
Manufacturer Suzuki Motor of America, Inc.
Components
Potential Number of Units Affected 8,613

 

Alternator may not Charge Battery

A short circuit of the stator wires may prevent the battery from properly charging, causing an engine stall and increasing the risk of a crash.

 

Summary

Suzuki Motor of America, Inc. (Suzuki) is recalling certain model year 2012-2016 DL650 motorcycles manufactured August 30, 2011, to October 12, 2015.

In the affected motorcycles, the alternator stator may have insufficient heat resistance, resulting in a short circuit of the stator wires.

 

Remedy

Suzuki will notify owners, and dealers will replace the stator, free of charge.

The recall is expected to begin in December 2016.

Owners may contact Suzuki customer service at 1-714-572-1490.

Suzuki’s number for this recall is 2A67.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Suzuki Motorcycle has a Recall

 

Date Nov. 25, 2016
Our ref. AF-1611251

 

TO: Selected Motorcycle Distributors
ATTN: Managing Director
Service Director or Manager
CC: Spare Parts Manager

 

SUBJECT: DL650A/XA, LT-A750X/XP Stator Assy Replacement Recall Campaign

Dear Sirs and Madams,

This letter is to inform you of the “Stator Assy Replacement Recall Campaign” for DL650A/XA L2-L6 and LT-A750X/XP L6-L7.

Due to the lack of heat resistant capacity of stator coil, the insulation material of wiring for the stator may be damaged by engine heat, and the short-circuit between wirings may occur. Continued use of motorcycle with this condition, the generating current by the stator coil may be reduced and the insufficient charging to the battery may cause. In the worst case, it can lead to the engine stalling during running and/or the engine may be impossible to restart.

In view of the nature of this problem, Suzuki Motor Corporation (SMC) has decided to carry out the Recall Campaign in your market. The details are explained in the following pages.

You are kindly requested to organize the Recall Campaign for the affected units in your market. If you are required to report to your authority, please contact them according to your law.

If you have affected units in your warehouse, you are required to remedy them before releasing to your dealers. You are also immediately required to instruct your dealers to remedy the affected unit in stock if any, before delivering them to the customers.

Please make sure that no customers will receive the affected units without appropriate Recall campaign remedy.

We apologize for any inconvenience this may cause to you. Your cooperation and assistance will be highly appreciated.

If you have any question, please don’t hesitate to contact us anytime.

 

Very truly yours,

Yasuhiro Kawai
Group Manager
Motorcycle Service Group
Motorcycle Operations
SUZUKI MOTOR CORPORATION

 

Action

1. For the affected units before retail sales, you are requested to remedy them before delivering them to the customers.
2. For the affected units after retail sales, contact the customers of the units to let them bring their vehicles to your authorized dealers.
3. Order the necessary number of parts to SMC Global Spare Parts & Accessories Dept. by e-mail using the attached Parts Order form of ANNEX4.

(Note: If spare parts are purchased from SDE, please order to SDE.)

4. Report to the authority according to your law.
5. Issue service bulletin to dealers and customer letter to owners. 6) Perform a corrective work following the repair instruction of Annex3.

 

Affected Models

Model / Production Period:

1. DL650A/XA L2-L6 produced from April 21, 2011 to October 14, 2016.
2. LT-A750X/XP L6-L7 produced from August 21, 2015 to November 11, 2016.

Affected VIN range and units quantity in your market: Please refer to attached VIN list of ANNEX2.

 

Replacement Parts

Initial Parts Order:

Please order the necessary number of parts from SMC Global Spare Parts & Accessories Dept. bv E-mail using the attached Parts Order form of ANNEX4.

(Note: If spare parts are purchased from SDE, please order to SDE.)

As of Dec. 2, 2016, SMC prepare approximately 30% of recall parts against affected units but we will stock additional 20% of parts by the beginning of March, 2017.

 

Additional Parts Order:

Please order the necessary number of parts through SCAN system.

Model	Part name	Part number	Q’ty	Contents
DL650A/XA	Stator set	32100-7820-RXO	1	STATOR ASSY (32101-17G13) x 1 GASKET, MAGNETO COVER (11483-1500) x 1 GASKET (12.1 x 16.2 x 3.7) (09168-12002) x 1 CLAMP (L:120) (09407-14408) x 1 GASKET (5.8 x 13 x 1.2) (09168-06023) x 2
LT-A750X/XP	Stator set	32100-31810-RXO	1	STATOR ASSY (32101-31G02) x 1 GASKET, MAGNETO COVER (11483-31GOO) x 1 GASKET (12.1 x 16.2 x 3.7) (09168-12002) x 1 O RING(09280-13007) x 1 GASKET(17413-33400) x 1 O RING (D:3.5) (17435-31GOO) x 1 O RING    (09280-22001) x 1

 

Note: As for DL650A/XA (Parts number: 32100-17820-RXO), please order the necessary number of parts in multiples of 90 as much as possible, because 90 pieces are packed in one box.

 

Warranty Reimbursement Information

This is a Recall campaign that is acceptable only one time for one unit.

Submit the warranty claim applications to SMC under the following terms.

Claim category		2 (Campaign)
Trouble Code		99 – AF
Basic code		EG9999
Model	Causal Part Name	Causal Part No.	Q’ty	Flat Rate(Hr)
DL650A/XA	Stator set	32100-17820-RXO	1	1.9
LT-A750X/XP	Stator set	32100-31810-RXO	1	2.5

 

Note: Engine oil and coolant

SMC allow to submit the engine oil and coolant cost as a sublet as shown in below.

In case of the sublet (Hr) in below is not compensate your genuine engine oil or coolant cost, please contact us with the evidence which shows cost of your genuine engine oil or coolant cost.

Model	Sublet
	Engine oil (Hr)	Engine coolant (Hr)
DL650A/XA	0.5
LT-A750X/XP	0.5	0.4

 

Repair Instruction

The repair instruction of ANNEX3 is available on SCAN FD.

Please download the files from below.

SCAN FD – Download – Service – Document Files for Motorcycle

ANNEX3: “ANNEX3_DL650_Repair_lnstruction_of_Stator_Replacement.docx”

“ANNEX3_LT-A750_Repair_lnstruction_of_Stator_Replacement.docx”

 

Implementation Date and Progress On Your Country

1) Implementation Date:

<PLAN>

Please fill following planning schedule in the ANNEXI and email to us by Dec. 2, 2016.

1. Recall campaign notification date to your authority, if required.
2. Recall campaign notification date to your dealers.
3. Start date of Recall Campaign notification letter mailing to customers.
4. Date of ordering parts for initial necessary quantity.
5. Quantity of parts ordered for initial portion.

 

<ACTUAL STATUS>

Please fill following latest information in the ANNEXI and email to us once a week until all the cells are completely filled out.

1. Recall campaign notification date to your authority, if required.
2. Recall campaign notification date to your dealers.
3. Start date of Recall Campaign notification letter mailing to customers.
4. Date of ordering parts for initial necessary quantity.
5. Quantity of parts ordered for initial portion.

We would like to ask you to provide the implementation date above to window person of SMC  Motorcycle Service Group.

2) Implementation Progress:

Please email the following information with your company name to your window person.

You are requested to email daily until Campaign execution rate reaches 80%.

1. Latest accumulated number of units completed.
2. Original number of affected unit.
3. Updated number of affected units, if adjusted.

 

Attachment:

ANNEX 1: Recall_campaign_notification_plan_form.xlsx

ANNEX 2: Country_name_VlN_List.xlsx

ANNEX 3: Please download from SCAN.

“ANNEX3_DL650_Repair_lnstruction_of_Stator_RepIacement.docx”

“ANNEX3_LT-A750_Repair_lnstruction_of_Stator_RepIacement.docx”

ANNEX 4: Recall_Campaign_Parts_Special_0rder_Form.xlsx

ANNEX 5: Sample_of_Customer_Letter.docx

END

 

 

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