Front Brake Master Cylinder Body Replacement Recall Campaign – 2022 Suzuki GSX1300RRQ/ZM2 (Hayabusa) motorcycles

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February 15, 2023 NHTSA CAMPAIGN NUMBER: 23V088000

Incorrect Position of Master Cylinder/FMVSS 122

A gap between the front brake pad and discs can extend the distance required to stop, increasing the risk of a crash.

 

NHTSA Campaign Number: 23V088000

Manufacturer Suzuki Motor USA, LLC

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 2,552

 

Summary

Suzuki Motor USA, LLC (Suzuki) is recalling certain 2022 GSX1300RRQ/ZM2 (Hayabusa) motorcycles. An incorrect position of the front brake master cylinder primary port could cause the port to become blocked, and result in a gap between the front brake pad and discs. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 122, “Motorcycle Brake Systems.”

 

Remedy

Dealers will replace the front brake master cylinder body, free of charge. Owner notification letters were mailed March 1, 2023. Owners may contact Suzuki’s customer service at 1-800-934-0934. Suzuki’s number for this recall is 2A99.

 

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.nhtsa.gov.

 

Check if your Suzuki Motorcycle has a Recall

 


February 27, 2023

SAFETY RECALL CAMPAIGN 2A99
2022 Hayabusa Front Brake Master Cylinder Body Replacement
Service Procedures

Recall service overview:

Replace the master cylinder body and piston cup set of the front brake master cylinder assembly. You will also replenish the brake fluid and bleed any air from the brake system. To read the full GS/GSX/GSX-R No. 259 Safety Recall Campaign bulletin,

 

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Issue Date:FEB.09,2023

Repair Instruction of Front Brake Master
Cylinder Body Replacement
GSX1300RM2

 

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Chronology of Principle Events

 

September 2, 2021

Suzuki Motor Corporation (SMC) received a Field Technical Information Report (FTIR) from its Portuguese distributor concerning a GSX1300R motorcycle front brake that was not working.

When the vehicle was inspected, it was found that the initial description was incorrect. It was not a case that the front brake was not working, rather that the condition was that the front brake lever travel could increase. The condition was resolved by repeated application of the front brake lever. It was not possible to investigate further as the condition had resolved, and the cause of the increased front brake lever travel could not be determined. The front brake master cylinder was collected for further investigation.

 

November 24, 2021

As a result of investigating the field sample part, it was confirmed that the outer circumference of the primary seal cup had swelled and flattened, and the distance between the primary seal cup and the primary pressure port was less than that of the in-house inventory. SMC was unable to determine if this finding was a causal factor.

 

December 29, 2021

SMC conducted testing of the field sample part and found that when the brake lever is fully released the primary seal cup could flatten, and in this condition the primary port may become blocked. When the brake fluid temperature decreases in this state, negative pressure is generated in the brake system and the brake caliper pistons retract into the caliper body, creating increased clearance between the brake pad and the brake disc. In this condition the front brake lever travel is increased in initial application.

 

February 9, 2022

The position of the primary port was changed to increase the distance from the primary port and the primary seal cup to prevent blockage if the primary seal cup flattens to the same degree as the field sample part.

 

March 23, 2022

The American distributor issued a FTIR reporting a complaint of spongy brakes and excessive brake lever travel. Sample parts related to the FTIR were collected.

 

April, 2022

Two additional FTIRs were issued by the American distributor regarding this matter. Sample parts related to the second FTIR were collected.

 

May 25, 2022

Vehicle brake performance testing was conducted with a front brake master cylinder collected from the market that exhibited a worst-case condition of blockage and SMC found that in this condition, satisfactory FMVSS compliance was confirmed. The cause of the seal cup flattening had not been determined, and SMC continued its investigation.

 

June 17, 2022

One additional FTIR was issued by the American distributor regarding this matter. Sample parts related to the FTIR were collected.

 

August, 2022

Three additional FTIRs were issued by the American distributor regarding this matter. Sample parts related to the second and third FTRs were collected.

 

September, 2022

Three additional FTIRs were issued by the American distributor regarding this matter. Sample parts related to the FTIRs were collected.

 

October 4, 2022

Flattened seal cups were analyzed and found to contain the same compound as exists in the master cylinder cap diaphragm (seal). Cause and effect of this factor was considered, and SMC continued its investigation.

 

November 29, 2022

One additional FTIR was issued by the American distributor regarding this matter. Sample parts related to the FTIR were collected.

 

December 21, 2022

One additional FTIR was issued by the American distributor regarding this matter.

 

January 25, 2023

SMC determined that the cause of the primary seal cup flattening was due to interaction of a compound present in the cap diaphragm that migrates into the brake fluid, and that this interaction could lead to primary port blockage and increased front brake lever travel.

 

February 9, 2023

Because a condition exists that could cause increased braking distance and that may result in a failure to comply with FMVSS 122, SMC decided to conduct a recall.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
SUZUKI GSX1300RRQ 2022

 


28 Associated Documents

Recall 573 Report – February 22, 2023

RCLRPT-23V088-9311.PDF 213.89KB

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Suzuki – Recall Campaign (Revised) – February 2023

RCMN-23V088-1143.pdf 113.91KB

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Suzuki – Chronology – February 2023

RMISC-23V088-0876.pdf 78.537KB

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Noncompliance Notice 573 Report

RCLRPT-23V088-1764.PDF 213.916KB

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Suzuki – Recall campaign notification plan form – February 2023

RCMN-23V088-3766.pdf 129.713KB

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Recall Acknowledgement

RCAK-23V088-6140.pdf 645.95KB

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Suzuki – Sample of the Announcement Letter – February 2023

RCMN-23V088-9256.pdf 76.013KB

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Suzuki – STOP RETAIL SALES and DELIVERY – February 2023

RCMN-23V088-1602.pdf 109.978KB

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Suzuki – Recall Campaign – February 2023

RCMN-23V088-7379.pdf 102.009KB

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Suzuki – Repair Instruction – February 2023

RCMN-23V088-6712.pdf 1746.417KB

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Remedy Instructions and TSB

RCRIT-23V088-0069.pdf 1325.629KB

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Suzuki – Recall Administration – February 2023

RCMN-23V088-8976.pdf 2245.886KB

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Suzuki – Recall Notification – February 2023

RCMN-23V088-5855.pdf 12165.61KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V088-7149.pdf 445.78KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V088-4482.pdf 179.09KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V088-1274.pdf 546.911KB

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Suzuki – Hayabusa Safety Recall Campaign Email – March 2023

RMISC-23V088-2119.pdf 313.982KB

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Suzuki – Request for Disposal of Inventory Parts – March 2023

RMISC-23V088-3127.pdf 132.989KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V088-7014.pdf 461.998KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V088-2309.pdf 449.687KB

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Suzuki – Email – June 2023

RMISC-23V088-6888.pdf 313.613KB

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Suzuki – Urgent Safety Recall Notice – July 2023

RMISC-23V088-6588.pdf 401.882KB

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Suzuki – Service Bulletin – July 2023

RCMN-23V088-3013.pdf 1181.803KB

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Suzuki – Service Bulletin – July 2023

RCMN-23V088-8041.pdf 4776.41KB

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Suzuki – Recall Announcement – July 2023

RMISC-23V088-3862.pdf 665.91KB

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Suzuki – Recall Notice – September 2023

RMISC-23V088-5548.pdf 761.284KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V088-7089.pdf 620.786KB

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Recall Quarterly Report #4, 2023-4

RCLQRT-23V088-2271.PDF 211.602KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V088&docType=RCL

 


 

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