Safety Recall Campaign GSX250RL8 Headlamp – 2018 Suzuki GSX250R Motorcycles

September 30, 2020 NHTSA CAMPAIGN NUMBER: 20V612000

Low and/or High Beam may Fail

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 SuzukieBay logo Motor of America, Inc.

Components EXTERIOR LIGHTING

Potential Number of Units Affected 2,040

 

Summary

SuzukieBay logo Motor of America, Inc. (SuzukieBay logo) is recalling certain 2018 GSX250R motorcycles. The low and/or high beam headlight may fail.

 

Remedy

SuzukieBay logo 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 SuzukieBay logo 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 SuzukieBay logo 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.

 


SUZUKIeBay logo MOTOR OF AMERICA, INC.

IMPORTANT SAFETY RECALL

This Notice Applies to Your SuzukieBay logo Motorcycle Identification Number (VIN)

XXXXXXXXXXXXXXXXX

 

October 9, 2020

Dear SuzukieBay logo Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

SuzukieBay logo 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 SuzukieBay logo 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. SuzukieBay logo 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 SuzukieBay logo Dealer at no cost to you for parts and labor.

 

What you should do:

Before having the recall repair performed, SuzukieBay logo 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 SuzukieBay logo 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 SuzukieBay logo published flat-rate time allowance for the repair, and the labor rate that an authorized SuzukieBay logo 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 SuzukieBay logo 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 SuzukieBay logo Dealer, please visit www.suzukicycles.com, click on Find a Dealer, enter your zip code, and select Go.

 

If you believe that SuzukieBay logo 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 SuzukieBay logo motorcycle.

 

Sincerely,

SuzukieBay logo Motor of America, Inc.

 

P.O. Box 1100, Brea, CA 92822-1100 • Phone (714) 996-7040

 


Chronology of Principle Events

 

April, 2017

SuzukieBay logo 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 SuzukieBay logo 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 SuzukieBay logo bulbs. The result of the comparison durability testing showed that aftermarket bulbs had filament breakage earlier than genuine SuzukieBay logo 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, SuzukieBay logo’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 SuzukieBay logo 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 SuzukieBay logo 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

MAKEMODELYEAR
SUZUKIGSX250R2018

 


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

RMISC-20V612-1836.pdf 78.85KB

 


Recall Acknowledgement

RCAK-20V612-1516.pdf 244.409KB

 


Manufacturer Notices(to Dealers,etc) – Revised

RCMN-20V612-9762.pdf 38.801KB

 


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

RCMN-20V612-0615.pdf 163.47KB

 


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

RMRP-20V612-4353.pdf 112.49KB

 


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)

RCMN-20V612-6392.pdf 35.375KB

 


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: https://www-odi.nhtsa.dot.gov/owners/Search NHTSA ID using the following complaint identification numbers: No VOQ’s are reported.


 

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  • More Down Road Visibility: SilverStar halogen headlights create a whiter light with more down road visibility that will enhance your overall experience on the road at night.
  • Whiter Light For Added Clarity: The combination of down-road, side road, and whiter light achieves more clarity during nighttime driving. More clarity improves contrast and makes it easier to see objects on and along the side of the road.
  • Confirm Fit: When using the Amazon Part Finder, be sure to confirm the POSITION and NOTES provided. For some vehicles, bulbs may fit some positions (fog light, low beam, high beam, or high/low beam), but not all. The POSITION and NOTES ensure Exact Fit! AVAILABLE IN: 9003, 9004, 9005, 9006, 9007, 9008/H1, H3, H7, H11, H13.
  • Reliable Design For Optimal Performance: SilverStar has a specially designed filament, propriety halogen gas mixture, and a unique lamp coating that shifts the color temperature towards a whiter light.

Last update on 2026-06-19 / Affiliate links / Images from Amazon Product Advertising API


 

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