September 30, 2020 NHTSA CAMPAIGN NUMBER: 20V612000
The sudden loss of low and/or high beams can reduce the driver’s visibility, increasing the risk of a crash.
NHTSA Campaign Number: 20V612
Manufacturer Suzuki Motor of America, Inc.
Components EXTERIOR LIGHTING
Potential Number of Units Affected 2,040
Summary
Suzuki Motor of America, Inc. (Suzuki) is recalling certain 2018 GSX250R motorcycles. The low and/or high beam headlight may fail.
Remedy
Suzuki will notify owners, and dealers will replace the headlight bulb and install a bulb retention spring clip, free of charge. The recall began March 29, 2021. Owners may contact Suzuki customer service at 1-844-352-4921.
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
What is the defect?
The filament in the high/low beam headlamp bulb may break prematurely, resulting in sudden loss of illumination,
which can reduce operator visibility and/or a clear view, increasing the risk of a crash.
What your dealership will do:
1) Verify the unit is affected as instructed below.
2) Replace the headlamp bulb and install a retention spring clip with the countermeasure parts.
3) Submit a warranty claim.
Affected Model
GSX250RL8
Model Year
2018
VIN Range
LC6DN11A_J1100008 ~ LC6DN11A_J1102919
Parts Ordering Information:
Model:
GSX250RL8
Part Description:
Bulb Set, Headlamp
(1) Bulb
(1) Clip, Headlamp
(1) Leaflet
Part Number:
35200-20810-RX0
Quantity Required:
1
NOTE:
The countermeasure part features vibration resistance.
Clip
Install the clip onto the hinge of the bulb holder spring to prevent the spring from becoming misaligned.
Follow the inspection and repair procedures as outlined in this Technical Service Bulletin (TSB).
Repair Procedure:
Removal:
1) Remove the front seat (refer to Section 9D Seat Removal and Installation).
2) Remove the negative battery lead wire (1).
3) Remove the right and left rear view mirrors (refer to Section 9D Rear View Mirror Removal and Installation).
NOTICE
The caps on the mirror fixing bolts can be damaged if not handled with care.
Use extra care not to damage the caps when removing the mirror fixing bolts.
4) Remove the under center cowling (refer to Section 9D Under Center Cowling Removal and Installation).
5) Remove the right and left side cowling assemblies (refer to Section 9D Side Cowling / Inner Cowling / Under Cowling Removal and Installation).
6) Remove the right and left under cowlings (refer to Section 9D Side Cowling / Inner Cowling / Under Cowling Removal and Installation).
7) Remove the right and left frame side cover assemblies (refer to Section 9D Frame Side Front Cover / Frame Side Lower Cover / Frame Side Cover Removal and Installation).
8) Remove the body cowling assembly (refer to Section 9D Windscreen / Body Cowling / Meter Front Panel Removal and Installation).
NOTE:
The windscreen does not need to be removed.
NOTICE
The headlamp lens can be damaged if not handled with care during removal and installation.
Use extra care not to damage the headlamp lens during removal and installation.
9) Remove the headlamp coupler (1) and bulb socket rubber cap (2).
10) Check to see if a plate (1) is installed at the hinge part of the headlamp bulb holder spring. If a D-shaped plate secures the retaining spring, it is not necessary to replace the bulb and install the clip.
No plate
Replace the headlamp bulb and add the clip.
Go to step 11
NOTE:
There is a washer under the screw.
With a plate
If you see a D-shaped plate (1) used to secure the retaining spring, then it is not necessary to replace the bulb and install the clip.
Go to step 15.
11) Unhook the bulb holder spring (1) from bracket of the headlamp body.
12) Install the clip as follows:
A) Align the center of the bulb holder spring (1) with the center of the screw (2).
B) As illustrated in below, pinch the clip (1) and insert the tab (2) onto the clip into the hole in the spring mount (3).
NOTE:
If the clip is accidentally dropped into the headlamp, reverse the headlamp and remove the clip.
C) Fully insert the clip (1) in the direction indicated by the arrow below.
D) Confirm the clip is installed correctly as shown below.
If the clip does not fit correctly, contact your Suzuki TSM.
Refer to the GSX250R Service Manual if it is necessary to replace the headlamp.
13) Replace with a countermeasure headlamp bulb (1).
NOTICE
Touching the glass portion of the countermeasure headlamp bulb with your fingers may deposit oils on the glass.
If you touch the bulb with your fingers, before installing the bulb, clean the glass of the bulb with a cloth moistened with alcohol or mild soapy water.
14) Hook the bulb holder spring(1) to bracket of the headlamp body.
15) Install the bulb socket rubber cap (1) and headlamp coupler (2).
16) Install the body cowling assembly (refer to Section 9D Windscreen / Body Cowling / Meter Front Panel Removal and Installation).
17) Install the right and left frame side cover assemblies (refer to Section 9D Frame Side Front Cover / Frame Side Lower Cover / Frame Side Cover Removal and Installation).
18) Install the right and left under cowlings (refer to Section 9D Side Cowling / Inner Cowling / Under Cowling Removal and Installation).
19) Install the right and left side cowling assemblies (refer to Section 9D Side Cowling / Inner Cowling / Under Cowling Removal and Installation).
20) Install the under center cowling (refer to Section 9D Under Center Cowling Removal and Installation).
21) Install the right and left rear view mirrors (refer to Section 9D Rear View Mirror Removal and Installation).
Tightening torque
Rear view mirror mounting bolt (a):
10 Nm (7.3 lbf-ft)
22) Connect the negative (–) battery lead wire (1)
23) Install the front seat (refer to section 9D Seat Removal and Installation.)
24) Final inspection:
- Confirm each part is set and tightened securely.
- Confirm the lights operate properly.
- Adjust the headlamp beam position (refer to Section 9B Headlamp Beam Adjustment).
- Set the time on the clock (Refer to Owner’s manual).
- Set the engine rpm indicator light (refer to the Owner’s Manual).
- When delivering the unit to the customer, provide them with the advisory pamphlet containing the recommendation to use a vibration-resistant bulb when replacing the headlamp bulb in the future.
SUZUKI MOTOR OF AMERICA, INC.
IMPORTANT SAFETY RECALL
This Notice Applies to Your Suzuki Motorcycle Identification Number (VIN)
XXXXXXXXXXXXXXXXX
October 9, 2020
Dear Suzuki Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Suzuki Motor Corporation (SMC) has decided that a defect which relates to motor vehicle safety exists in certain 2018 model-year GSX250R motorcycles. According to our records, you own one of the motorcycles affected by this recall.
What is the problem?
SMC is initiating a safety recall campaign of certain 2018 GSX250R motorcycles. The filament of the headlamp bulb may fail prematurely, resulting in the headlamp going out during operation, increasing the risk of a crash. What is Suzuki Motor Corporation doing to solve the problem?
SMC is analyzing this issue and is working to develop a repair procedure and the necessary repair parts. Suzuki Motor of America, Inc. (SMAI) will mail you a second notification letter in the future when the repair procedures and repair parts are available.
This safety recall repair will be performed by a Suzuki Dealer at no cost to you for parts and labor.
What you should do:
Before having the recall repair performed, Suzuki recommends the following:
- Do not operate your motorcycle at night or in a dark condition until the recall has been completed.
- If you choose to ride in daytime, please observe the following instructions:
- Check your state law for daytime headlight operation requirements.
- Before each ride, inspect the low and high beam headlight functions for proper operation.
- If you find the headlight is not operational, take the motorcycle to your Suzuki Dealer for a no-charge inspection and repair.
- In the event of a high or low beam filament failure, the remaining high or low beam function can be used to temporarily operate the motorcycle.
What to do if you receive this notice in error:
This notice was mailed to you according to the latest information that is available to us. If you no longer own the motorcycle described in this notice, please complete and return the attached Change of Address/Ownership card to SMAI, and forward this recall information to the current owner (if known).
Customer reimbursement for repairs before this Safety Recall Notification:
If your motorcycle is included in this recall and you have paid for repairs to address the defect that led to this recall, you may be eligible for full or partial reimbursement. Please note the following conditions for reimbursement:
- Only repairs made to address the defect that led to this recall are Additional expenses such as towing, car rental, accommodations, damage repairs, etc., will not be reimbursed. Reimbursement will not be provided for routine scheduled maintenance.
- Reimbursement may be limited to the suggested list price for parts, the Suzuki published flat-rate time allowance for the repair, and the labor rate that an authorized Suzuki Dealer in the same area would charge for the same
- Reimbursement claims may also be excluded when adequate documentation is not submitted by the claimant. This includes a proof of ownership, a repair order, and proof of payment for the
To apply for reimbursement, contact SMAI’s Customer Service Department at (714) 572-1490.
Who to contact if you experience problems:
Your Suzuki Dealer can provide you the fastest response to your questions or concerns about this safety recall campaign. If you have any difficulty with this recall campaign, you may contact SMAI’s Customer Service Department for assistance at (714) 572-1490 during the hours of 7:00 AM to 4:30 PM Pacific Time. Please have your vehicle identification number (VIN) ready when calling. The VIN for your vehicle is listed at the top of this notice.
If you need to locate your nearest Suzuki Dealer, please visit www.suzukicycles.com, click on Find a Dealer, enter your zip code, and select Go.
If you believe that Suzuki has failed to provide the safety recall campaign service without charge or is unable to do so within a reasonable time, you may submit a complaint to the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington D.C., 20590 or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-888-424-9153) or go to www.safercar.gov.
We apologize for any inconvenience this recall campaign causes you. We hope you understand that your safety and satisfaction are important priorities for us.
We sincerely regret any inconvenience this Important Safety Recall may cause, but we are certain you understand our interest in your safety and your continued satisfaction with your Suzuki motorcycle.
Sincerely,
Suzuki Motor of America, Inc.
P.O. Box 1100, Brea, CA 92822-1100 • Phone (714) 996-7040
Chronology of Principle Events
April, 2017
Suzuki Motor Corporation (SMC) received a Field Technical Information Report (FTIR) from its Japanese distributor concerning a GSX250R motorcycle headlamp that was not working. SMC found that the lowbeam filament was broken and deformed. SMC judged that this likely occurred as a result of an impact applied to the vehicle with the low beam illuminated.
July, 2017
SMC received information from the Japanese distributor that the headlamp bulb retaining spring of a new motorcycle had become dislodged when a Japanese dealer replaced the original headlamp bulb with an aftermarket bulb at the customer’s request. As result of their investigation, SMC found that when the bulb retention spring is unhooked, the spring can drop down so that it is not properly retained between the retention washer and housing. SMC developed a design change to the headlamp assembly as a countermeasure to prevent the bulb retention spring from becoming dislodged from its original position during bulb replacement.
September, 2017
SMC received a third FTIR about headlight bulbs with broken filaments from the Japanese distributor.
October to November, 2017
As a result of investigation of the collected bulb from the motorcycle that was the subject of the third FTIR from the Japanese distributor, SMC found that the headlamp filament was broken, and melted spherical ends were found at the broken point of the filament. This failure was determined to be consistent with breakage due to excessive voltage. The cause of the excessive voltage could not be identified by only examining the returned bulb.
January, 2018
SMC received the first FTIR from Suzuki Motor of America, Inc. (SMAI), indicating that the low beam did not turn on in a GSX250R motorcycle. SMC determined during investigation of the failed headlamp bulb that it was an aftermarket bulb.
SMC received an FTIR from the United Kingdom distributor that indicated that a single motorcycle had experienced two headlamp bulb failures. The bulb that broke the second time was an aftermarket bulb. SMC also found that the low beam filament was broken, and that the bulb retaining spring was worn and installed out of alignment with the headlamp bulb.
May, 2018
SMC received a fifth FTIR from SMAI and was told that a field investigation was possible.
June, 2018
An on-site vehicle inspection of the affected motorcycle described above was performed, and SMC learned from user comments that the motorcycle was used for commuting to Mexico and was ridden over several speed bumps near the border. SMC confirmed through testing that operation with impacts caused by riding over speed bumps would not cause bulb failure in such a short period of time as seen in the market.
August, 2018
SMC received nine FTIR’s from SMAI, four of which involved headlamps with aftermarket bulbs. SMC conducted comparison durability testing with aftermarket bulbs and genuine Suzuki bulbs. The result of the comparison durability testing showed that aftermarket bulbs had filament breakage earlier than genuine Suzuki bulbs. In three of the nine cases, SMC was unable to collect or investigate the actual parts, so SMC does not know if these cases involved aftermarket bulbs.
September, 2018
SMC had become aware of more than 20 cases of similar failures in the world markets. Based on FTIRs received, SMC understood that the similar failures involved the bulb spring becoming displaced when the bulb spring hook is removed, and that this may not be noticed by the individual performing the bulb replacement due to inability to visually confirm that the reassembly work was done correctly. Based on the assumption that a replaced bulb may not be properly fixed and will rattle if the spring is displaced, it was judged that this may create the possibility of filament breakage due to vibration. SMC decided to prepare countermeasure parts to prevent the bulb retention spring from becoming dislodged from its proper position when the bulb is replaced.
November, 2018
SMC continued analysis of FTIRs. During this analysis, questions arose about the causal relationship between the bulb retention spring coming off and filament breakage, so a retest was conducted. It was found that detachment of the bulb retaining spring is not a factor in bulb failure. Instead, it was determined that if the rubber cap behind the bulb was not installed correctly, the vibration would be amplified and the filament may break in the high speed range near the engine speed limiter.
January, 2019
SMC decided to issue a Service Bulletin to distributors, providing tips for headlamp bulb replacement that would reduce the chance that the bulb retention spring would be displaced during bulb replacement.
April, 2020
SMC received a Preliminary Evaluation (PE) information request from NHTSA. It was decided to repurchase two motorcycles from the U.S. market which experienced headlamp failure, to restart the investigation into the cause of the problem.
May-July, 2020
SMC responded to the PE information request in three submissions covering information about the failures, Suzuki’s actions and views, and the results of the repurchased vehicle survey.
August, 2020
As of August 2020, SMC was aware of 37 vehicles in the United States with headlamp bulb failures out of 2,040 vehicles mass-produced prior to the change in the retention structure of the spring.
September, 24, 2020
On September 24, 2020, SMC decided to make a defect determination and file a Part 573 report. The cause of the bulb breakage is still being investigated and recall corrective action has not yet been determined.
October-November, 2020
An interim customer notification letter using SMAI sales records was sent to customers on October 9, 2020 informing that a safety defect had been determined for certain GSX250R motorcycles. A supplemental mailing was issued on November 16, 2020 using DMV registration records to customers not identified in the initial interim mailing.
SMC continued to conduct testing at headlamp bulb filament-resonant engine speeds using a headlamp assembly equipped with the original-design spring retention structure. SMC confirmed filament breakage as a result of this extended running distance testing. The broken filament inspected from this testing had similar appearance to the broken filaments of bulbs collected from customer-owned motorcycles.
SMC conducted additional testing by subjecting headlamp bulbs to the same vibration directly as had been measured during vehicle vibration tests. This testing confirmed that the bulb filaments could be broken by vibration in a relatively short amount of time, however the amount of time for a filament to break was inconsistent.
SMC conducted additional testing using a headlamp assembly equipped with the revised spring retention structure and determined that the amount of bulb filament vibration was lower than with a headlamp assembly with the original-design spring retention structure when subjected to the same test conditions.
December, 2020
SMC has not yet determined the reason why bulb filament vibration is different between the original-design and revised-design spring retention structure. This is still under investigation.
January, 2021
SMC determined that the revised spring retention structure by itself increased the spring tension that is applied to the headlamp bulb, and that this increased spring tension reduced the amplitude of the headlamp bulb filament movement compared to the original headlamp spring retention structure design. The degree of filament movement measured in the revised headlamp assembly was consistent with filament movement other model Suzuki motorcycles that do not exhibit premature headlamp filament breakage.
February, 2021
SMC conducted testing of a countermeasure headlamp bulb that contained an additional filament support for a period of 100 hours while subjected to vibration equivalent to a worst-case riding condition of 7,700~8,100RPM (260~290Hz) without a bulb filament failure.
SMC determined that maximum filament vibration of the countermeasure bulb, when installed in an original 2018 model year design headlamp housing, was less than the filament vibration exhibited by other model Suzuki motorcycles that do not exhibit premature headlamp filament breakage.
February 24, 2021
SMC determined after further review of parts shipment information that all 2018 GSX250R production received headlamp assemblies of the original design that preceded the change in the headlamp bulb spring retention structure that was applied to 2019 model year GSX250R production. As a result, the affected recall population increases by 60 vehicles to 2,100.
February 26, 2021
SMC decided to conduct a recall to replace the headlamp bulbs of affected vehicles with the countermeasure bulb.
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| SUZUKI | GSX250R | 2018 |
29 Associated Documents
ISSUED Owner Notification Letter(Part 577)
RCONL-20V612-0849.pdf 287.752KB
Recall Quarterly Report #2, 2021-2
RCLQRT-20V612-4099.PDF 211.244KB
IMPORTANT SAFETY RECALL REMINDER GSX250R/RZ HEADLAMP BULB 2A95 recall reminder 7-23-2021
RMISC-20V612-8696.pdf 426.658KB
Chronology
RMISC-20V612-8603.pdf 89.783KB
Recall Quarterly Report #1, 2021-1
RCLQRT-20V612-0669.PDF 211.139KB
Manufacturer Notices(to Dealers,etc) – GS/GSX/GSX-R No. 253 March 22, 2021 SAFETY RECALL CAMPAIGN 2A95 GSX250RL8 Headlamp Bulb
RCMN-20V612-5758.pdf 962.638KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-20V612-9907.pdf 169.995KB
Chronology of Principle Events
RMISC-20V612-0494.pdf 81.083KB
Chronology of Principle Events
Recall Acknowledgement
RCAK-20V612-1516.pdf 244.409KB
Manufacturer Notices(to Dealers,etc) – Revised
ISSUED Owner Notification Letter(Part 577)
RCONL-20V612-8796.pdf 524.414KB
Manufacturer Notices(to Dealers,etc) – Boletín de Servicio
RCMN-20V612-3913.pdf 1404.194KB
Defect Notice 573 Report
RCLRPT-20V612-9555.PDF 212.697KB
Manufacturer Notices(to Dealers,etc) – Service Motorcycle/ATV Division GS/GSX/GSX-R No. 252 October 1, 2020
Recall 573 Report-Amendment 1
RCLRPT-20V612-2076.PDF 212.684KB
Manufacturer Notices(to Dealers,etc) – MOTORCYCLE / ATV Division GS/GSX/GSX-R No. 251 September 28, 2020
RCMN-20V612-9591.pdf 330.207KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-20V612-4403.pdf 679.863KB
Manufacturer Reimbursement Plan
Manufacturer Notices(to Dealers,etc) – Final Notification
RCMN-20V612-0736.pdf 191.545KB
Manufacturer Notices(to Dealers,etc) – March 22, 2021
RCMN-20V612-1238.pdf 1004.274KB
Recall 573 Report-Amendment 4
RCLRPT-20V612-6224.PDF 213.606KB
Recall 573 Report-Amendment 5
RCLRPT-20V612-4871.PDF 213.603KB
Recall 573 Report-Amendment 2
RCLRPT-20V612-2199.PDF 213.605KB
Recall 573 Report-Amendment 3
RCLRPT-20V612-4135.PDF 213.606KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-20V612-0707.pdf 644.429KB
Manufacturer Notices(to Dealers,etc)
Recall Quarterly Report #3, 2021-3
RCLQRT-20V612-5411.PDF 211.331KB
2A95 recall reminder 11-23-2021
RMISC-20V612-2536.pdf 413.13KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V612&docType=RCL
1 Associated Investigation
Loss of headlights
NHTSA ID: PE20004
Dated opened: April 7, 2020
The Office of Defects Investigation (ODI) is opening this Preliminary Evaluation (PE) on 2018 Model Year Suzuki GSX 250 R series motorcycles based on allegations of complete loss of forward illumination. ODI has received multiple manufacturer field reports describing headlight failures. In one of the reports, the rider claims that both the low and hi-beams were inoperative. Failure of a motorcycle headlight can result in a reduction of visibility for the driver while riding at night and a reduction in conspicuity while riding at any time.
Additionally, ODI discovered communications between Suzuki and their dealerships concerning a design change to improve bulb housing on the subject vehicles.
A Preliminary Evaluation has been opened to determine the frequency of this failure mechanism and understand the conditions that might influence this malfunction on the subject vehicles.
The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/Search NHTSA ID using the following complaint identification numbers: No VOQ’s are reported.
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- 500% BRIGHTER - Each H4 led headlight bulb HB2 9003 high and low beam has 3pcs top automotive grade LED chips ( 50W, 15000LM, 6500K cool white ) which make it 5 times brighter than traditional halogen bulbs.
- EXCELLENT BEAM PATTERN - The H4 led headlight bulb HB2 9003 high and low beam use same beam pattern as original halogen bulbs but can deliver wider and further range light on road, without any dark spots nor glare to the oncoming traffic to ensure you a safer driving.
- CANBus-READY FOR 98% VEHICLES - The H4 led headlight bulb HB2 9003 high and low beam can work with 98% vehicle computer systems without any error nor radio interference. (NOTE: Very few models may require installation of additional CANBus decoder, you can contact us for confirmation before purchase)
- 50,000 HOURS LIFESPAN - The 9003 led headlight bulb is equipped with a full aviation aluminum body plus a 12,000 RPM powerful turbo-cool-fan to ensure you the longest life duration while making bright and continuous light.
- EASY INSTALLATION - The H4 led headlight bulb hi/lo beam can be installed within just 10 mins by simply plugging and playing. It is also IP68 waterproof, dustproof and cold-resistant (-40℉~+300℉) that you are worry-free to use under all types of weather conditions.
- 2 sided design with 4 LED chips as light source features hi/lo beam switch and delivers wider and longer beam pattern. 2 LED chips light up for low beam and all 4 LED chips light up together for high beam. 6000K white, 12W and 1400lms each bulb can perfectly replace original BA20D 35W halogen bulb in motorcycle by providing more brilliant illumination.
- Built-in IC circuit can only work for DC motorcycles with the voltage range starting from 9V to 85V to prevent LED bulb from being damaged by voltage variation and spikes, meanwhile extend the range of fitments. Exclusive fanless heat sink is moved upside of BA20D collar and features halogen 1:1 all-in-one design to ease installation, provide with secure temperature and longer life span.
- BA20D LED bulb is applied to replace dual hi/lo beam headlamp for motorcycle, motorbike, scooter, ATV, UTV, snowmobile, street bike, touring bike, cruiser, sport bike, naked bike, street fighter, off-road bike, dirt bike, motorcross, electric or gas powered bicycle, adult or kids moped, mobility scooter, e-bike and more.
- Fits for 50cc, 110cc, 125cc, 140cc, 150cc, 200cc, 250cc Chinese Taotao scooter, Znen, Jonway, Baron, Tank Scooter, KTM, Yamaha, Honda Motor, Suzuki, Arctic Cat, Ducati, Indian, Kawasaki, Moto Guzzi, Polisport, Polaris, Triumph, Victory, Can-Am, with the headlight bulb base of BA20D and DC type motor.
- Cross Reference: BA20D, H6, S2. Notice: before your purchase, please make sure 1.Your original bulb as BA20D with double contacts 2.The dimension of LED bulb works for your installation space. 3.Headlight assembly without bulb cap inside. 4. Not for AC Motors.
Last update on 2022-05-18 / Affiliate links / Images from Amazon Product Advertising API
Last update on 2022-05-18 / Affiliate links / Images from Amazon Product Advertising API
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