Speedometer and Odometer May Fail – 2019-2020 Suzuki UH200 Motorcycles

April 28, 2021 NHTSA CAMPAIGN NUMBER: 21V299000

Speedometer and Odometer May Fail

The operator will not know the vehicle speed without a functioning speedometer, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V299

Manufacturer Suzuki Motor USA, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 270

 

Summary

Suzuki Motor USA, LLC (Suzuki) is recalling certain 2019-2020 UH200 motorcycles. The speedometer assembly resistors may corrode and cause a loss of power to the wheel speed sensor, preventing the speedometer and odometer from displaying information.

 

Remedy

Dealers will replace the speedometer assembly, free of charge. Owner notification letters were mailed May 24, 2021. Owners may contact Suzuki customer service at 714-572-1490 or www.suzukicycles.com.

 

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

 

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Motorcycle / ATV

GV/AN/UH No. 055

May 20, 2021

 

SAFETY RECALL CAMPAIGN 2A96

2019 & 2020 Burgman 200 Speedometer Recall

Affected Models:	Certain 2019 & 2020 Burgman 200 (UH200AL9-M0) Scooter Models
Affected Departments:	Management, Service, Warranty, Sales, Parts, Accessories
Attachments:	Sales Bulletin 21-063 (Burgman 200 Stop Sales) & Customer Notification Letter

 

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

Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists in certain 2019 and 2020 model-year Burgman 200 scooters.

 

STOP DELIVERY OF AFFECTED VEHICLES IMMEDIATELY

DO NOT SELL OR DELIVER an affected scooter to a customer until you have completed or verified completion of the repair procedures outlined in this bulletin. It is a violation of Federal law to sell or deliver any new motorcycle, scooter, ATV, or item of motor vehicle equipment subject to a safety recall campaign under a sale or lease until the defect or noncompliance has been corrected. In addition, selling an unrepaired affected motorcycle, scooter, or ATV is a direct violation of your Suzuki dealer agreement and may lead to additional sanctions.

 

What is the defect?

Due to insufficient corrosion resistance on speed sensor power supply circuit parts inside the speedometer assembly, corrosion may cause a poor electrical connection between the speed sensor and its electric power supply. In the worst case, the speedometer and odometer may not work properly.

 

What your dealership will do:

• Check your unsold inventory to see if you have any affected Burgman 200 models (use the identification process on the following page). If so, order the necessary parts, repair the scooter and then submit a warranty request to Suzuki Motor USA, LLC (SMO). You must do this before selling or transferring the scooter.

• Check your sales records to contact customers to whom you have sold an affected Burgman 200. Contact the owner of an affected scooter to alert him/her that you are ordering the necessary recall repair parts. Let the customer know there will be no charge for parts or labor. Set an appointment to install the parts, perform the recall service, and then submit a warranty request to SMO.

• If your dealership is contacted by someone who has an affected Burgman 200, but you did not sell the scooter, let the owner know you can assist with the recall service. Let the customer know there will be no charge for parts or labor. You can then order the necessary recall repair parts. Set an appointment to install the parts, perform the recall service, and then submit a warranty request to SMO.

 

Verify if the scooter is affected by the safety recall:

Confirm the recall status by checking the vehicle identification number (VIN) against the Vehicle Master in Suzuki Connect to see if the scooter is eligible for the campaign inspection and replacement procedure. If you have a question regarding scooter eligibility, call Tech-Line at (714) 996-7480 or contact your Suzuki Technical Service & Parts Manager (TSPM).

 

Affected model	Model year	VIN Range
UH200AL9	2019 (L9)	MLCCH41A#K1600001 – MLCCH41A#K1600120
UH200AM0	2020 (M0)	MLCCH41A#L1600001 – MLCCH41A#L1600150

 

Note: “#” indicates any check digit from 0 to 9 and X.

 

What Suzuki Motor USA, LLC, will do:

During the week of May 24, 2021, Suzuki Motor USA, LLC (SMO) will mail notifications to owners of affected Burgman 200 scooters for whom we have information. The notice instructs the customer to contact a Suzuki dealer to schedule an appointment for the repair.

If you have sold an affected Burgman 200 to a customer prior to receiving this bulletin, please contact the customer immediately to arrange for the scooter to be returned to your dealership for this safety recall campaign.

 

Ordering parts for the Safety Recall Campaign:

You will be responsible for ordering parts for this recall using normal parts ordering procedures for each scooter.  If you have any questions regarding parts orders, please contact SMO Parts Coordination at (714) 854-2165.

 

Parts ordering information:

Part description:	SPEEDOMETER, ASSY
Part number:	34100-12JU2-RX0
Quantity:	1

 

Identification of recall campaign parts (new speedometer):

 

Warranty claim processing:

Submit a warranty claim for each recall repair immediately upon completion. This campaign requires you to file a warranty claim using ONE of the methods described below.

Suzuki Connect Short Campaign Claim: The Short Campaign Claim will reimburse you for the replacement of the speedometer assembly and 0.8 hour labor.

CAMPAIGN SUZUKI CONNE	A96 UH200A SPEEDOMETER CT SHORT FORM INSTRUCTIONS
CLAIM INFORMATION:
CLAIM NUMBER:	XXXXX,X (Dealer enters number)
ENTRY TYPE:	VIN, Model/Frame or Control/Sequence # (Dealer chooses)
REPAIR DATE:	Enter date of repair
MILEAGE:	Enter mileage at repair date
CAMPAIGN NUMBER:	2A96
LABOR OPERATION:	SE9999

 

Suzuki Connect Long Campaign Claim:  The Long Campaign Claim will reimburse you for the replacement of the speedometer assembly and 0.8 hour labor, and additional parts and labor as authorized by your TSPM.

 

CAMPAIGN 2A96 UH200A SPEEDOMETER SUZUKI CONNECT LONG FORM INSTRUCTIONS
CLAIM INFORMATION:
CLAIM NUMBER:	XXXXX,X (Dealer enters number)
ENTRY TYPE:	VIN, Model/Frame or Control/Sequence # (Dealer chooses)
REPAIR DATE:	Enter date of repair
MILEAGE:	Enter mileage at repair date
CAMPAIGN NUMBER:	2A96
LABOR TIME:	As authorized by your TSPM
PARTS INFORMATION:
ADDITIONAL PARTS:	Additional parts as authorized by your TSPM
AUTHORIZATION:	Only needed if additional parts or labor claimed
FAILURE DESCRIPTION:
DESCRIPTION OF DEFECT:	Speedometer replacement
DESCRIPTION OF REPAIR:	Performed service campaign repair per service bulletin

 

IMPORTANT – Recording the odometer reading:

It is imperative the odometer reading (mileage) be accurately recorded on the repair order when the customer brings the scooter in for recall service. This information is required to record on the ODOMETER CHANGE LABEL that must be applied to the scooter (see page 9 of this bulletin). The original mileage is also required for proper warranty claim processing and for the customer to keep for future transactions related to the scooter.

If the scooter is traded in or sold to a new owner, the current owner must declare that the speedometer/odometer was replaced and what the mileage was when the replacement occurred. Please explain this requirement to your customers and advise them to keep the repair order copy with the original mileage in a safe place.

 

SPEEDOMETER REPLACEMENT RECALL SERVICE

 

SPEEDOMETER ASSEMBLY

Part number on original speedometer:   34100-12J*0 or 34100-12J*1

Part number on new, recall speedometer:  34100-12JU2

Recall service speedometer, order this number:  34100-12JU2-RX0

 

Precautions:

• To avoid getting burned, do not touch the engine and exhaust system until they have cooled.

• Before the repair work, wash dirt from the scooter to prevent dirt contamination.

• When removing parts to be reused, arrange them in an orderly manner so they can be reinstalled in the proper order and orientation.

• Refer to the Burgman 200 Service Manual (99500-31523-03E) for any details or procedures not mentioned in these instructions.

 

Required tools:

• Phillips screwdriver, #2 tip, medium to long shaft

• Phillips screw driver, #3 tip, medium to long shaft

• Phillips screw bit #2 socket (to fit to torque wrench)

• 10 mm socket wrench -or- wrench

• Torque wrench, must read 1.5 lb-ft (2.0 N.m, 0.2 kgf-m)

 

IMPORTANT – Record the odometer reading & oil service interval:

Before starting the recall repair work, record the current mileage on the odometer and the remaining distance to the next oil change using the following procedure:

1. Turn the ignition switch to the “ON” position to display the odometer so you can record the current mileage (a).

2. Press and hold the ADJ button for 2 seconds. The odometer will then display the last reset mileage (b) while blinking three times and then display the current interval setting (c).

3. Record the remaining distance of oil change interval calculated by the formula “(b)+(c)-(a)”.

4. Turn off the ignition switch.

 

Speedometer removal:

1. Remove the right floor mat 1.

2. Remove the battery cover by removing the screws 2.

 

3. Disconnect the battery negative lead wire 3.

 

4. Remove the front cover screws 4.

 

5. Pull the front cover 5 forward, pull down to disconnect the hooks 6 on both sides of the front cover.

 

6. Pull the front cover 1 forward and remove it.

 

 

NOTE: There are hooks 2 under the front cover.

 

7. Remove the windscreen 3 by removing the windscreen screws 4.

 

8. Remove the lower meter panel mounting screw 5.

 

9. Remove the speedometer mounting screws 1.

 

NOTE: Be careful to not drop the screws and other items inside the bodywork.

 

10. Remove the lower meter panel 2.

 

NOTE: Be careful to not damage the hooks 3 when removing the lower meter panel 2 .

 

Speedometer replacement:

1. Disconnect the speedometer electrical connector 1.

2. Replace the original speedometer 2 with the new speedometer.

3. Connect the electrical connector 1 to the new, mounted speedometer.

 

4. Tighten the speedometer mounting screws 3 to the specified torque and install the lower meter panel 4 and brace 5.

 

Tightening torque:

Speedometer mounting screw 3:

1.5 lb-ft (2.0 N.m, 0.2 kgf-m)

 

Removed parts installation:

1. Install the removed parts in the reverse order of removal.

NOTE:  Refer to the Service Manual if guidance is required.

 

Applying odometer replacement label:

1. Included with the speedometer is an ODOMETER CHANGE LABEL 1.

2. Using a fine-tip, permanent marker (such as a black, ultra-fine point Sharpie brand marker) record the following information on the Odometer Change Label:

• Original odometer mileage

• Technician name

• Suzuki dealership name

• Suzuki dealer number

• Repair date ODOMETER CHANGE Completed

ODOMETER CHANGE LABEL (99924-00609)	Completed Example

 

3. Adhere the filled-out change label 1 to the right, inner side of the under seat cargo tray 2, adjacent to the existing white tire specification label.

 

NOTE: The right side of the scooter is the side opposite of the side stand.

Make sure the surface of the cargo tray is clean and dry so the change label will stick to its surface.

If required, additional ODOMETER CHANGE LABELS can be ordered from the Suzuki Parts Department using the part number 99924-00609.

 

Final check & meter reset:

1. Verify that each part is properly installed and the mounting hardware is tightened securely.

2. Verify that the new speedometer works properly as follows:

• Check that the LEDs (FI indicator or MIL 1, ABS indicator light 2, ECO mode indicator 3, and ECT indicator 4) immediately illuminate when the ignition switch is turned ON.

• Check that the other LEDs (High-beam indicator 5, and turn signal indicators 6 operate properly when the dimmer or turn signal switches are operated.

 

3. Set the time on the clock (refer to Owner’s Manual).

4. When returning the repaired scooter, educate the customer about the following points:

• The odometer will only show mileage from your quality control test ride.

• Show the customer the scooter’s actual mileage recorded on the repair order and how many miles until the next oil change.

• Offer to reset the oil change interval for the customer, once the odometer reaches 600 miles.

 

NOTE: The oil change interval on the new speedometer can not be set or reset until the scooter has been ridden 600 miles (1000 km).

 

SALES BULLETIN 21-063, STOP SALES BURGMAN 200 (page 1 of 2)

 

SALES BULLETIN 21-063, STOP SALES BURGMAN 200 (page 2 of 2)

 

CUSTOMER NOTIFICATION LETTER (page 1 of 2)

 

CUSTOMER NOTIFICATION LETTER (page 2 of 2)

 

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IMPORTANT SAFETY RECALL

This Notice Applies to Your Suzuki Vehicle Identification Number (VIN)

MLCCH41XXXXXXXXXX

 

May 24, 2021

 

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 has decided that a defect which relates to motor vehicle safety exists in certain modelyear Burgman 200 scooters.  According to our records, you own one of the scooters affected by this recall campaign.

 

What is the defect and what will your dealership do to correct it?

Suzuki Motor Corporation is initiating a safety recall campaign of 2019 & 2020 Burgman 200 scooters.

Due to insufficient corrosion resistance on speed sensor power supply circuit parts inside the speedometer assembly, corrosion may cause a poor electrical connection between the speed sensor and its electric power supply. In the worst case, the speedometer and odometer may not work properly.

Your Suzuki dealer will verify if your scooter requires the recall service and, if necessary, order and install an improved speedometer assembly. This recall service will take approximately one hour to complete.

Parts are available now, and there will be no charge to you for any recall service-related parts or labor.

WARNING

Operating your scooter without having the recall service performed increases the risk of a crash. To minimize the risk of a crash: Please do not ride nor allow anyone else to ride your scooter until this recall service has been completed. If you must ride your scooter before this safety recall service has been completed, check the speedometer and other items for proper operation as outlined in the “INSPECTION BEFORE RIDING” checklist in section 4 of your owner’s manual before each ride.

 

What you should do:

Make sure you are prepared for the recall service by taking the following steps:

• Contact your dealer as soon as possible to make an appointment for the recall service. Be prepared to provide them with the VIN of your scooter (provided at the top of this notice).

• Please take this notice to your dealer to help your dealer process your claim.

 

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 Suzuki scooter described in this notice, please complete and return the attached Change of Address/Ownership card to Suzuki Motor USA, LLC, and forward this recall information to the current owner (if known).

Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 

Customer reimbursement for repairs prior to this Safety Recall Notification:

If your scooter 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 reimbursable. 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 Service Provider in the same area would charge for the same repair.

• 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 repair.

 

To apply for reimbursement, contact the Suzuki Motor USA, LLC Customer Service Department at (714) 572-1490 during the hours of 7:30 AM to 4:30 PM Pacific Time.

 

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 the Suzuki Motor USA, LLC, Customer Service Department for assistance at (714) 572-1490 during the hours of 7:30 AM to 4:30 PM Pacific Time. Please have your vehicle identification number (VIN) ready when calling.

If you need to locate your nearest Suzuki Motorcycle Dealer, please visit www.suzukicycles.com and click on the “FIND A DEALER” tab, which is located in the upper right corner of our website.

If you believe that Suzuki Motor USA, LLC, 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.

 

Sincerely,

 

Suzuki Motor USA, LLC

 

3251 E. Imperial Highway, P.O. Box 1100, Brea, CA 92822-1100 • Phone (714) 996-7040

 

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2A96 UH200 Campaign

 

Customer reimbursement for repairs prior to this Safety Recall Notification:

If your vehicle 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 reimbursable. 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 Service Provider in the same area would charge for the same repair.

• 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 repair.

To apply for reimbursement, contact Suzuki Motor USA, LLC’s Customer Service Department at (714) 572-1490

 

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Chronology of Principle Events

 

February 28, 2019

Suzuki Motor Corporation (SMC) received an initial report from the distributor in Korea that the speedometer of a UH125 scooter had stopped working.

 

July, 2019

Because of an increase in the number of reported speedometer failures, SMC sent its person in charge to the supplier in Taiwan to investigate the reason for the failures.  As a result of the investigation, SMC determined that the reason for the speedometer failures was due to corrosion of the resistors in the wheel speed sensor power supply circuit that is integral to the speedometer assembly.  SMC believed that the corrosion might be caused by exposure to sulfur gas that is released as a natural byproduct from the rubber boot surrounding the electrical harness coupler that is then attached to the speedometer assembly.

 

October, 2019

SMC determined that a change to the speedometer assembly manufacturing specification by the supplier had occurred in April 2018 that added a second supplier of resistors used in the speed sensor power supply, and that the resistor corrosion condition was limited to resistors sourced from this second supplier.  The speedometer supplier discontinued use of resistors from the second component supplier.

 

November 19, 2019

SMC received a report from the U.S. distributor that the speedometer of a UH200 scooter did not display speed. (Note that the UH125 and UH200 scooters share a common wheel speed signal power supply design).

 

February 2020

SMC confirmed that the root cause of the speedometer operation failure was due to resistor corrosion caused by sulfur gas emanating from the rubber harness connector boot.  At this time, SMC did not believe that the condition resulted in a safety defect.

 

March, 2020

SMC performed additional analysis of resistors sourced from both resistor part suppliers and confirmed that the resistors from the second supplier that was added in April 2018 had lower resistance to corrosion from sulfur gas than the resistors sourced from the original resistor part supplier.

 

April, 2020

SMC conducted research into available technical literature on sulfur off-gassing which reported that sulfur gas emissions from the type of rubber material used for the harness boot generally stop after about one year following manufacture.  This supposition was supported by the decreasing number of cases of speedometer non-operation and the approximate two-year age of the vehicles that had been manufactured during the period when the affected resistors were being used.  SMC made an initial determination that a market action was not required.

 

June 3, 2020

SMC received a second report of speedometer non-operation from the U.S. distributor for a UH200 scooter.

 

August, 2020

Because the amount of time elapsed between manufacture of the and speedometer failure did not agree with the initial research information on sulfur off-gassing, SMC resumed its investigation.

 

December, 2020

SMC collected samples of rubber boots in good condition of approximately two-years of age and investigated the amount of sulfur remaining in the rubber material.  SMC determined that some sample rubber boots continued to release sulfur gas more than two years after manufacture.

 

April 22, 2021

SMC determined that the resistors in the speed sensor power supply circuit could have inadequate resistance to corrosion and could develop poor circuit continuity resulting in the loss of speedometer function.  SMC decided to conduct a safety recall to replace the speedometer assemblies of the affected vehicles.

 

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2 Affected Products

Vehicle

MAKE	MODEL	YEAR
SUZUKI	UH200	2019-2020

 

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16 Associated Documents

Manufacturer Notices(to Dealers,etc) – Bulletin No: 21-063 Date: April 27, 2021 STOP RETAIL SALES and DELIVERY

RCMN-21V299-4680.pdf 150.614KB