3A01 – ABS Hydraulic Unit Flare Nut Tightening – 2024 Suzuki GSX1300R

SEOCONTENT-START

Reimbursement notification for 3A01 campaign included in customer notification letter Customer reimbursement for repairs prior to 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 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.

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CONFIDENTIAL
Motorcycle Service Group Overseas Service Department
8686 Miyakoda-cho, Hamana-ku, Hamamatsu-shi, Shizuoka, Japan 431-2102 Tel: 81-53-528-8118, Fax: 81-53-528-8141
TO: Suzuki Motorcycle Distributors ATTN.: Managing Director
Service Manager
SUBJECT: GSX1300R(Hayabusa) ABS Hydraulic Unit Flare Nut Tightening Recall
Campaign
Dear Sirs and Madams, This letter is to inform you of the “ABS Hydraulic Unit Flare Nut Tightening Recall Campaign” for GSX1300RRQM4 and GSX1300RRQ2M4(Hayabusa) produced from Jul. 7, 2023 to Dec. 1, 2023. We were informed from our production plant that in the piping of the brake system, the tightening torque of the flare nut for fastening the brake pipe to the ABS unit may insufficient due to improper tightening work of the nut. If the motorcycle continues to be used in this condition, in the worst case, the loosening of the nut may cause brake fluid leakage and increase the braking distance. 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, Shinji Ishikawa
Department General Manager Overseas Service Department Suzuki Motor Corporation Page 1 of 3 Date Jan. 18, 2024
Our ref. JE-240118A Page 2 of 3 Action
For the affected units before retail sales, you are requested to remedy them before delivering them to the customers.
1) Check stock status
2) Confirm repair work procedure
3) Perform a repair work
4) Report completion to SMC with ANNEX2 VIN list of stock units.
For the affected units after retail sales, contact the customers of the units to let them bring their vehicles to your authorized dealers.
1) Check status of affected units
2) Report to the authority according to your law.
3) Issue service bulletin to dealers and customer letter to owners.
4) Perform a corrective work following the repair instruction of ANNEX3. Affected Models
Model: GSX1300RRQM4, GSX1300RRQ2M4(Hayabusa)
Production Period: From Jul. 7, 2023 to Dec. 1, 2023
Affected VIN range and units quantity in your market: Please refer to attached VIN list of ANNEX2.
Please fill “Completion date” in ANNEX2 Sheet ”Stock”, and send it back to us after you complete the work. Replacement Parts
Replacement Parts are not necessary for this campaign. 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 Trouble Code Basic code 2 (Campaign) 97-JE MD9999 Model
GSX1300RRQM4, GSX1300RRQ2M4 Part Name HOSE ASSY,UNIT TO FR
BK CLPR Part No.
59400-10L00 Q’ty 0 Flat Rate(Hr) 0.9 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: “GSX1300R_Repair_Instruction_of_Tightening_ABS_Hydraulic_Unit_Flare_ Nuts.doc” Implementation Date and Progress
1) Implementation Date:
Please fill following planning schedule in the Microsoft Forms (Link of the webpage) or ANNEX1 (Excel file) and send back to us by January. 31, 2024.
(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) Recall campaign notification date to distributor if you have resold affected unit to other distributor.
Please fill following latest information in the Microsoft Forms (Link of the webpage) or ANNEX1 (Excel file) and send back 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) Recall campaign notification date to distributor if you have resold affected unit to other distributor. 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 units.
(3) Updated number of affected units, if adjusted. Attachment:
ANNEX 1: Recall_campaign_notification_plan_form.xlsx
ANNEX 2: Country_Name_VIN_List.xlsx
ANNEX 3: GSX1300R_Repair_Instruction_of_Tightening_ABS_Hydraulic_Unit_Flare_ Nuts.doc ANNEX 4: Sample_Of_Customer_Letter
END
Page
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Issue Date: Jan 18, 2024
©Suzuki Motor Corporation, 2024. All rights reserved. Workflow
1. Confirmation of Affected Vehicles Page 2 2. Affected V.I.N. Range · Page 3 3. Countermeasure Operations
3-1. Required Tools · Page 3
3-2. Countermeasure Page 4
3-3. Work Procedure · Page 5
3-3-1. Fuel Tank Removal Page 5
3-3-2. Brake Pipe Flare Nuts Tightening · Page 9
3-3-3. Brake Fluid Check Page 10
3-3-4. Fuel Tank Installation Page 10 3-4. Final Check Page 15 1 1. Confirmation of Affected Vehicles
Check the Vehicle Identification Number (V.I.N.) if the vehicle is applicable unit to this replacement.
V.I.N.
V.I.N. Location The frame front right side V.I.N 2 2. Affected V.I.N. Range
Affected V.I.N. range is shown as below.
NOTE:
∙ “#” indicates any check digit from 0 to 9 and X.
∙ NOT all vehicles in the below V.I.N. range are affected. Model GSX1300RRQM4, GSX1300RRQ2M4 SPEC E03 E33 V.I.N. Range JS1EJ11B#R7100201 – JS1EJ11B#R7101144 JS1EJ11D#R7100027 – JS1EJ11D#R7100246 3. Countermeasure Procedure
3-1. Required Tools
∙ General Tool
Tool Name Size, Special Tool Number
Ratchet handle
Socket wrench 10 mm
Hexagon socket wrench 4 mm, 5 mm, 6mm
Torque wrench 4.0 N·m (0.41 kgf-m, 2.95 lbf-ft) to 23 N·m (2.3
kgf-m, 17.0 lbf-ft)
Flare nut socket wrench *1 10 mm (16 N·m(1.6 kgf-m, 11.5 lbf-ft)) Pliers
*1 : Sample photo 3 NOTE:
When a flare nut socket as shown in the figure is used, a difference occurs between the set value of the torque wrench and the actual torque. Set the torque value based on the effective length of the socket and wrench to be used.
Example)
Effective length of torque wrench: A mm Effective length of flare nut socket: B mm Specified torque: 16 N·m (1.6 kgf-m, 12.0 lbf-ft)
In the above case, the set value is “16 × A ÷ (A + B)“. Make the torque wrench and flare nut socket straight. 3-2. Countermeasure
・ Tighten the brake pipe flare nuts (2 places) of ABS unit.
・ In case brake fluid leakage is found, check the brake fluid level. And if the brake fluid level is below the lower limit line, replenish the brake fluid up to the specified amount. Precautions
・ To avoid getting burned, do not touch the engine and exhaust system until they have cooled.
・ Before the repair work, wash dirt off from the vehicle so that removed parts are kept free from dust.
・ When 2 or more persons work together, pay attention to the safety of each other.
・ When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
・ Keep away from fire or spark.
・ During disassembling, use care to minimize spillage of gasoline.
・ Spilled gasoline should be wiped off immediately.
・ Work in a well-ventilated area.
・ When replenishing brake fluid, take care not to get dust into the fluid.
・ Use a torque wrench to tighten fasteners to the specified torque. Refer to the service manual for the details not mentioned in the instructions. 4 3-3. Work Procedure NOTE:
By removing the battery, the SDMS mode setting is initialized to A mode and the engine rpm indicator light setting is changed to OFF. 3-3-1. Fuel Tank Removal
1) Turn the ignition switch OFF.
2) Remove the front seat bolts (1) and front seat (2). 3) Disconnect the battery (–) lead wire (1). 4) Remove the fasteners and bolt from the meter panel (1). 5 5) Remove the meter panel (1) in the direction as shown in the figure with unhooking the hooks. 6) Remove the left side meter panel as in steps 4) and 5). 7) Remove the fuel tank cap cover bolts and remove the fuel tank cap cover (1). 8) Remove the hook, fasteners (1) and bolts as shown in the figure. 6 NOTICE: To prevent damage to frame, remove the nut
(1) from the side cowling assembly. 9) Unhook the side cowling assembly (1) from the protrusion (2) of the bracket. 10) Remove the fuel tank front cover bolt (1).
11) Pull the side cowling assembly (2) in the direction as shown in the figure to make the space and remove the fastener (3).
NOTICE:
Do not pull the side cowling assembly too wide as it may damage the side cowling assembly. NOTE:
Be careful not to drop the fastener (3). 12) Pull the left side cowling assembly and remove the fastener as in steps 8) through 11). 7 13) Unhook the hooks and disconnect the fasteners (1) to remove the fuel tank front cover (2). 14) Remove the fuel tank front bolts (1) from the frame. 15) Lift and support the fuel tank.
16) Disconnect the fuel pump coupler (1) from the fuel pump.
17) Place a clean rag under the fuel feed hose (2).
18) Pull the retainer (3).
19) Disconnect the fuel feed hose joint (4) from the fuel pump.
20) With EVAP Control System : Disconnect the surge hose (5) and fuel tank water drain hose (6) from the fuel tank.
Without EVAP Control System : Disconnect the fuel tank breather hose (5) and fuel tank water drain hose
(6) from the fuel tank. 8 21) Remove the fuel tank rear bracket bolts (1) and rear brake master cylinder reservoir tank bracket bolt (2). 22) Lift up the rear side of fuel tank, and then remove the fuel tank rear bolt (1) and fuel tank(2).
23) Remove the fuel tank rear bolt spacer (3) from the fuel tank. 3-3-2. Brake Pipe Flare Nuts Tightening
1) Tighten the brake pipe flare nuts (1) to the specified torque.
Tightening torque
Brake pipe flare nut ( a ): 16 N·m (1.6 kgf-m, 11.5 lbf-ft)
NOTICE:
・ Make sure to hold the brake pipe when tightening the flare nut, or it may be misaligned.
・ Do not allow the torque wrench to contact with the surrounding pipes or other parts, when tightening the brake pipe flare nut to the specified torque. Otherwise, the brake pipe flare nut may not tighten to the
specified torque. 9 3-3-3. Brake Fluid Leakage Check
1) Check the around the brake pipe flare nut to make sure there is no brake fluid leakage.
NOTE:
If brake fluid leaks, clean the brake fluid adhesion with water.
Check the brake fluid level. When the brake fluid level is below the lower limit line, replenish the brake fluid to the specified amount. 3-3-4. Fuel Tank Installation
Install the fuel tank in the reverse order of removal. Pay attention to the following points:
NOTICE:
Be sure not to bend or twist the hoses when installing. 1) Attach the fuel tank rear bolt spacer (1) to the fuel tank.
2) Tighten the fuel tank rear bolt (2) to the specified torque.
Tightening torque
Fuel tank rear bolt ( a ): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) 3) Tighten the fuel tank rear bracket bolts (1) and
rear brake master cylinder reservoir tank bracket bolt
(2) to the specified torque.
Tightening torque
Fuel tank rear bracket bolt ( a ): 10 N·m (1.0 kgf-m,
7.5 lbf-ft)
Rear brake master cylinder reservoir tank bracket bolt ( b ): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) 10 4) Connect the fuel pump coupler (1) to the fuel pump while confirming that it clicks.
5) Connect the fuel feed hose joint (2) to the fuel pump.
6) Lock the retainer (3).
7) With EVAP Control System : Connect the surge hose
(4) and the fuel tank water drain hose (5) to the fuel tank.
Without EVAP Control System : Connect the fuel tank breather hose (4) and the fuel tank water drain hose
(5) to the fuel tank. NOTE:
・ Face the white mark of the surge hose to the left side.
・ Face the white mark of the fuel tank water drain hose to front side. 8) Remove a rag.
9) Tighten the fuel tank front bolts (1) to the specified torque.
Tightening torque
Fuel tank front bolt ( a ): 5.5 N·m (0.56 kgf-m,
4.05 lbf-ft) NOTICE: When installing the fuel tank, do not pinch the throttle cables (2). 10) Install the fuel tank front cover and tighten the fuel tank front cover bolt (1) to the specified torque. Tightening torque
Fuel tank front cover bolt ( a ): 4.0 N·m (0.41 kgf-m, 2.95 lbf-ft)
11) Pull the side cowling assembly (2) in the direction as shown in the figure to make the space and install the fastener (3). 11 NOTICE:
Do not pull the side cowling assembly too wide as it may damage the side cowling assembly. NOTE:
Be careful not to drop the fastener (3). 12) Attach the removed nut (2) to the side cowling assembly (1). 13) Hook the side cowling assembly (1) to the protrusion
(2) of the bracket. 12 14) Tighten the under cowling bolt (1) and side cowling assembly bolt (2) to the specified torque. Tightening torque
Under cowling bolt ( a ): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)
Side cowling assembly bolt ( b ): 10 N·m (1.0 kgf-m, 7.5 lbf-ft) 15) Perform the work on the left side cowling assembly as in steps 10) through 14). 16) Tighten the fuel tank cap cover bolts (1) to the specified torque.
Tightening torque
Fuel tank cap cover bolt ( a ): 5.5 N·m (0.56 kgf-m,
4.05 lbf-ft) 17) Install the meter panel (1) in the direction as shown in the figure with hooking the hooks. 13 18) Install the fasteners (1) and meter panel bolt (2) to the meter panel (3), and then tighten the meter panel bolt
(2) to the specified torque.
Tightening torque
Meter panel bolt ( a ): 4.0 N·m (0.41 kgf-m, 2.95 lbf-ft) 19) Install the left side meter panel as in steps 17) and 18).
20) Connect the battery negative (–) terminal (1). 21) Slide the front seat (1) into bracket and tighten the front seat bolts (2) to the specified torque. Tightening torque
Front seat bolt ( a ): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
NOTE:
・ Align the front sheet hole (3) with the frame hole (4).
・ Check that the cushion (5) is not detached. 14 15
3-4. Final Check
1) Check if there is any rag left.
2) Check that each part is set and tightened securely.
3) If the front brake lever grasp or the rear brake pedal depresses softly, inspect it to see if air is mixed in. If you find any anomalies, examine the brake fluid and bleed the air.
4) Set the date and time. (Reference: Owner’s Manual)
5) For vehicle subjected to air bleeding in step 3), drive the motorcycle on a dry road surface and front or rear brakes are operated independently to check if its braking performance is adequate. Additionally, check for any unusual noise.
6) Notify the customer that the mode setting of the driver assist system is initialized when the vehicle is
returned.

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<97-JE> Recall campaign notification plan form 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)
Recall campaign notification date to distributor if you have resold affected unit to other distributor. 5) Date of ordering parts for initial necessary quantity 6) 7) Quantity of parts ordered for initail portion (by Air, by Sea) Note 0000A Suzuki Motor Corporation Japan Asia Feb/21/2024 Mar/1/2024 Mar/1/2024 Feb/21/2024 Feb/21/2024 by Air: 50
by Sea: 100 Plan Actual by Air: by Sea:
We would like to ask you to provide this information to your window person of overseas service group by Jan. 31, 2024. In case that the dates are not finalized at the due date above, please enter the estimated dates. You can provide this information by using Microsoft Forms. Please click on the link below to use Microsoft Forms.
https://forms.office.com/r/YGYj8u24EE

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LE
Continued >>
Motorcycle / ATV Bulletin No: 24-012 Date: January 18, 2024
IMPORTANT SAFETY RECALL
STOP RETAIL SALES and DELIVERY
Suzuki Motor Corporation has determined that a safety defect exists in certain 2024 Hayabusa (GSX1300RRM4) & Hayabusa 25th Anniversary Edition (GSX1300RRZM4) models: Model GSX1300RRM4
& GSX1300RRZM4 SPEC E03 E33 V.I.N. Range JS1EJ11B#R7100201 – JS1EJ11B#R7101144 JS1EJ11D#R7100027 – JS1EJ11D#R7100246 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Suzuki Motor Corporation (SMC) is initiating a safety recall campaign to tighten the brake pipe flare nuts on the motorcycle’s ABS unit to the proper torque. Do not sell or deliver any new or used, affected Hayabusa motorcycle until the ABS Hydraulic Unit Flare Nut Tightening Recall service has been completed. Service Bulletin & Safety Recall Repair:
Information about performing the ABS Hydraulic Unit Flare Nut Tightening Recall service will be provided in a Service Bulletin coming on or after the week of January 29, 2024. Parts Availability & Ordering:
Parts are not required to perform the recall service. Suzuki Motor USA, LLC (SMO) may provide additional information regarding potentially related parts availability and ordering in the Service Bulletin mentioned above. Customer Notification Letters:
SMO expects to notify retail customers of this safety recall on or after the week of January 29, 2024. How to Verify if a Hayabusa requires the Recall Service:
This recall only affects certain 2024 (M4) Hayabusa models. Use the Vehicle History function of Suzuki CONNECT to determine if a particular Hayabusa requires the ABS Hydraulic Unit Flare Nut Tightening Recall service. If so,
all service, and submit a warranty request as described in the bulletin. Motorcycle / ATV Bulletin No: 24-012 Date: January 18, 2024
2/2
If you need any additional information, please contact the Suzuki TECH-LINE (at 714-996-7480) or your Technical Service and Parts Manager (TSPM). We apologize for this inconvenience and will do everything possible to resolve this situation as quickly as possible. Thank you for your continued support and understanding.
Chris Coons
Senior Manager, Motorcycle Sales Planning and Administration

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ANNEX 4
SAMPLE of the Announcement Letter to the Owners of the Affected Vehicle
IMPORTANT RECALL NOTICE
Dear SUZUKI Owner:
SUZUKI DISTRIBUTOR has decided to implement a Recall Campaign for certain GSX1300RRQM4 and GSX1300RRQ2M4 vehicles. According to our records, you own one of the vehicles that are affected by this Recall campaign.
We were informed from our production plant that in the piping of the brake system, the tightening torque of the flare nut for fastening the brake pipe to the ABS unit may insufficient due to improper tightening work of the nut. If the motorcycle continues to be used in this condition, in the worst case, the loosening of the nut may cause brake fluid leakage and increase the braking distance.
Instruction has been sent to the authorized Suzuki dealers. Please contact your authorized Suzuki
dealer and have your vehicle take the necessary rework.
This rework will be performed at no cost to you for parts and labor and it can be completed in less
than 0.9H if you have an appointment.
If your dealer unfortunately fails to make this repair without charge or within a reasonable period of
time, we would like to recommend you to kindly consult SUZUKI DISTRIBUTOR at .
If you no longer own this vehicle, please kindly inform or your
authorized Suzuki dealer of the change of owner information.
We are very sorry for any inconvenience this Recall campaign may cause, but we are certain that
you understand our interest in your continued satisfaction with Suzuki products.
Sincerely yours,
Suzuki Distributor

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SSAALLEESS
Continued >>
SALES
Motorcycle / ATV Bulletin No: 24-012 Revised date: January 19, 2024
Original date: January 18, 2024
IMPORTANT SAFETY RECALL
STOP RETAIL SALES and DELIVERY
Suzuki Motor Corporation has determined that a safety defect exists in certain 2024
Hayabusa (GSX1300RRM4) & Hayabusa 25th Anniversary Edition (GSX1300RRZM4) models:
Model
SPEC
V.I.N. Range
GSX1300RRM4
& GSX1300RRZM4
E03
JS1EJ11B#R7100201 – JS1EJ11B#R7101144
E33
JS1EJ11D#R7100027 – JS1EJ11D#R7100246
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Suzuki Motor Corporation (SMC) is initiating a safety recall campaign to tighten the brake pipe flare nuts on the motorcycle’s ABS unit to the proper torque. Do not sell or deliver any new or used, affected Hayabusa motorcycle until the ABS Hydraulic Unit Flare Nut Tightening Recall service has been completed.
Service Bulletin & Safety Recall Repair:
Information about performing the ABS Hydraulic Unit Flare Nut Tightening Recall service will be provided in a Service Bulletin coming on or after the week of January 29, 2024.
Parts Availability & Ordering:
Parts are not required to perform the recall service. Suzuki Motor USA, LLC (SMO) may provide additional information regarding potentially related parts availability and ordering in the Service Bulletin mentioned above.
Customer Notification Letters:
SMO expects to notify retail customers of this safety recall on or after the week of January 29, 2024.
How to Verify if a Hayabusa requires the Recall Service:
This recall only affects certain 2024 (M4) Hayabusa models. Use the Vehicle History function of Suzuki CONNECT to determine if a particular Hayabusa requires the ABS Hydraulic Unit Flare Nut Tightening Recall service. If so, perform the recall service, and submit a warranty request as described in the bulletin.
Consequences of Non-Compliance:
ALL NEW SUZUKI VEHICLES IN DEALER INVENTORY THAT ARE SUBJECT TO A RECALL OR CUSTOMER SATISFACTION CAMPAIGN INITIATED BY SMO MUST BE REPAIRED BEFORE THESE VEHICLES ARE SOLD OR DELIVERED BY THE DEALER TO THE RETAIL CUSTOMER. FAILURE TO DO SO IS A VIOLATION OF FEDERAL LAW, THE SUZUKI POWERSPORTS DEALER SALES AND SERVICE AGREEMENT (THE “DEALER AGREEMENT”), AND SMO’S SALES POLICY REGARDING FACTORY SAFETY RECALL OR SAFETY MODIFICATION PROGRAMS (THE “POLICY”). A COPY OF THE POLICY IS AVAILABLE ON SUZUKI CONNECT FOR YOUR REFERENCE.
Motorcycle / ATV Bulletin No: 24-012 Date: January 18, 2024
2/2
Consequences of Non-Compliance (continued):
FURTHER, FAILURE TO COMPLY WITH THE INSTRUCTIONS OF SMO REGARDING COMPLIANCE WITH RECALLS OR OTHER SAFETY OR PRODUCT IMPROVEMENT CAMPAIGNS OR PROGRAMS, AND/OR FAILURE TO MAKE A GOOD FAITH EFFORT TO COMPLY WITH THE FEDERAL CLEAN AIR ACT, THE NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT, THE CONSUMER PRODUCT SAFETY ACT, OR ANY OTHER LAWS, ORDERS, RULES, OR REGULATIONS REGARDING RECALLS OR OTHER SAFETY OR PRODUCT IMPROVEMENT CAMPAIGNS OR PROGRAMS CONSTITUTES A BREACH OF THE DEALER AGREEMENT AND IS A VIOLATION OF SMO POLICY REFERENCED ABOVE. A DEALER MAY BE HELD RESPONSIBLE FOR ANY PRODUCT DAMAGE AND/OR PERSONAL INJURIES RESULTING FROM SUCH FAILURE.
For more information on your dealership’s responsibilities and consequences of non-compliance, please review Sales Bulletin 21-054.
If you need any additional information, please contact the Suzuki TECH-LINE (at 714-996-7480) or your Technical Service and Parts Manager (TSPM). We apologize for this inconvenience and will do everything possible to resolve this situation as quickly as possible.
Thank you for your continued support and understanding.
Chris Coons
Senior Manager, Motorcycle Sales Planning and Administration

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-038
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Suzuki Motor USA, LLC JAN 23, 2024 NHTSA Recall No. : 24V-038 Manufacturer Recall No. : 3A01 Manufacturer Information :
Manufacturer Name : Suzuki Motor USA, LLC Address : 3251 East Imperial Highway
Brea CA 92821-6795
Company phone : 714-996-7040
Population :
Number of potentially involved : 993 Estimated percentage with defect : 13 %
Vehicle Information :
Vehicle 1 : 2024-2024 Suzuki GSX1300R Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : The recall population was determined based on production records.
Production Dates : JUL 07, 2023 – NOV 28, 2023 VIN Range 1 : Begin : JS1EJ11B5R7100201 End : JS1EJ11B2R7101144 VIN Range 2 : Begin : JS1EJ11D2R7100027 End : JS1EJ11D3R7100246 ✔ Not sequential
✔ Not sequential Description of Defect :
Description of the Defect : The brake fluid pipe flare nut installation torque for the brake fluid supply lines attached at the anti-lock brake system module (ABS module) that supply the front and rear brake calipers may have been tightened to less than the correct torque specification. In the worst-case, the flare nuts could loosen over time and brake fluid could leak from the ABS module body at the pipe connections. If a pipe connection allows fluid leakage, brake system performance could be affected. In the worst case, compliance with FMVSS 122 may not be met.
FMVSS 1 : 122 – Motorcycle brake systems FMVSS 2 : NR
Description of the Safety Risk : Brake fluid leakage could result in an increase in brake lever/pedal travel and reduced braking performance, increasing the risk of a crash.
Description of the Cause : The assembly process documentation lacked clarity and production-line worker training was insufficient, leading to assembly error. Identification of Any Warning
that can Occur : Part 573 Safety Recall Report 24V-038 Page 2 Involved Components : Component Name 1 : HOSE ASSY,UNIT TO FR BK CLPR
Component Description : Brake pipe assembly from the ABS module to the front brake caliper Component Part Number : 59400-10L00-000 Component Name 2 : HOSE ASSY,UNIT TO RR BK CLPR
Component Description : Brake pipe assembly from the ABS module to the rear brake caliper Component Part Number : 69400-10L00-000 Supplier Identification : Component Manufacturer
Name : Suzuki Motor Corporation Address : 300 Takatsuka-cho, Chuo-ku
Hamamatsu-shi Shizuoka-ken Foreign States 432-8611
Country : Japan Chronology :
The chronology is provided as a separate document. Description of Remedy :
Description of Remedy Program : Brake pipe flare nut connection tightness at the ABS module will be
inspected and the flare nuts tightened to the correct torque specification. The brake fluid level will be inspected and adjusted if necessary. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : The remedy does not involve a part replacement. The correct tightening torque has been applied to the brake pipe flare nut connections from December, 2023 production. Recall Schedule : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-038
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Recall Schedule : The notification schedule shown is the current estimate. Suzuki will
provide notification of any schedule changes as necessary.
Planned Dealer Notification Date : JAN 29, 2024 – JAN 29, 2024
Planned Owner Notification Date : FEB 05, 2024 – FEB 05, 2024
* NR – Not Reported

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SAFETY RECALL CAMPAIGN 3A01
2024 Hayabusa ABS Hydraulic Unit Flare Nut Tightening
Affected Models: Certain 2024 Hayabusa (GSX1300RR/RRZM4) motorcycles
Affected Departments: Management, Service, Warranty, Sales, Parts, Accessories
Attachments: Sales Bulletin 24-012 (Hayabusa Stop Sales) & Customer Notification Letter
Reference: Hayabusa GSX1300R Service Manual (99500-10L00-03E)
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 2024 model-year Hayabusa (GSX1300RRM4) and Hayabusa 25th Anniversary Edition (GSX1300RRZM4) motorcycles.
GS/GSX/GSX-R No. 264
January 31, 2024
SERVICE
Motorcycle / ATV
STOP DELIVERY OF AFFECTED VEHICLES IMMEDIATELY
DO NOT SELL OR DELIVER an affected motorcycle 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 non-compliance 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?
Suzuki Motor Corporation is initiating a safety recall campaign to tighten the brake fluid pipe flare nuts on the anti-lock brake system module (ABS unit) to the proper torque specification.
The brake fluid pipe flare nut installation torque for the brake fluid supply lines attached at the ABS unit that supply the front and rear brake calipers may have been tightened to less than the correct specification. If the motorcycle continues to be used in this condition, in the worst case, loosening of a flare nut may cause brake fluid leakage and increase braking distance, increasing the risk of a crash.
Continued on the following page >>
Contents of this bulletin:
What Suzuki Motor USA, LLC will do……………………………………………………………………………….2
Parts are not required for this Safety Recall Campaign………………………………………………………2
What your dealership will do……………………………………………………………………………………………2
Affected VIN range………………………………………………………………………………………………………..2
Checking recall repair status on Suzuki CONNECT……………………………………………………………2
Warranty claim processing information……………………………………………………………………………..3
Recall service procedure…………………………………………………………………………………………4 – 15
Suzuki dealer STOP SALES bulletin……………………………………………………………………….16 – 17
Customer notification letter…………………………………………………………………………………….18 – 19
2 / 19
Use Suzuki CONNECT to verify recall status:
Before performing the recall repair on a Hayabusa, first verify the repair needs to be performed by checking the motorcycle’s VIN and accessing the Vehicle Master Inquiry on Suzuki Connect and checking the repair status.
If the recall repair needs to be performed, you will see the message “CAMPAIGN NOT YET PERFORMED.”
If you have a question regarding motorcycle eligibility, call TECH LINE at (714) 996-7480 or contact your Suzuki Technical Service & Parts Manager (TSPM).
Model
SPEC
V.I.N. Range
GSX1300RRM4 & GSX1300RRZM4
E03
JS1EJ11B#R7100201 – JS1EJ11B#R7101144
E33
JS1EJ11D#R7100027 – JS1EJ11D#R7100246
VIN Location
Continued on the following page >>
What your dealership will do:
1.
Please prioritize completion of the recall service for your affected Hayabusa customers. For their safety and satisfaction, we strongly suggest you do not wait for them to contact you, but you should take the initiative to contact them to set an appointment to perform the recall service as soon as possible. Provide them the premium service that ownership of Suzuki’s flagship sportbike conveys. If you need support to address a customer’s needs or concerns, please call TECH LINE at (714) 996-7480 or contact your Suzuki Technical Service & Parts Manager (TSPM).
2.
Check your unsold inventory to see if you have any affected 2024 Hayabusa models (refer to “Use Suzuki CONNECT to verify recall status” below). If so, perform the recall service, and then submit a warranty request to Suzuki Motor USA, LLC (SMO). You must do this before selling or transferring the motorcycle.
3.
Check your sales records to contact customers to whom you have sold an affected Hayabusa motorcycle. Contact the owner of an affected motorcycle to alert him/her that you will need to perform the recall service and there will be no charge for parts or labor. Set an appointment to perform the recall service, and then submit a warranty request to SMO.
4.
If your dealership is contacted by someone who has an affected Hayabusa, but you did not sell the motorcycle, let the owner know you can assist with the ABS Hydraulic Unit Flare Nuts Tightening recall service. Let the customer know there will be no charge for parts or labor. Set an appointment to perform the recall service, and then submit a warranty request to SMO.
•
NOT all motorcycles in the VIN range above are affected, verify recall status with Suzuki CONNECT.
•
“#” indicates any check digit from 0 to 9 and X.
Affected model VIN range:
What Suzuki Motor USA, LLC, will do:
During the week of February 5, 2024, Suzuki Motor USA, LLC (SMO) will mail notifications to owners of affected Hayabusa motorcycles 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 Hayabusa to a customer prior to receiving this bulletin, please contact the customer immediately to arrange for the motorcycle to be returned to your dealership for this safety recall campaign.
Parts are not required for this Safety Recall Campaign:
In normal situations, new parts will not be needed to complete this recall service. If you find parts are required to complete the recall service, contact Suzuki’s TECH-LINE at (714) 996-7480 or contact your Technical Service & Parts Manager (TSPM) to discuss the situation.
New, repaired units from Suzuki warehouses:
New, unsold and crated GSX1300RR/RZM4 motorcycles delivered to dealers from Suzuki warehouses after 01/25/2024 should have already received the ABS Hydraulic Unit Flare Nut Tightening Recall service. Proof of repair is blue paint marks applied to the tightened flare nuts. You must still verify the motorcycle’s recall repair status using Suzuki CONNECT (see above).
3 / 19
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 0.9 hour labor (for tightening the brake fluid pipe flange nuts to the ABS unit).
CAMPAIGN 3A01 GSX1300RM4 ABS HYDRAULIC UNIT FLARE NUT TIGHTENING
SUZUKI CONNECT 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:
3A01
Suzuki CONNECT Long Campaign Claim: The Long Campaign Claim will reimburse will reimburse you 0.9 hour labor (for tightening the brake fluid pipe flange nuts to the ABS unit), plus additional parts and labor as authorized by your TSPM.
Reminder:
All LONG CLAIM FORMS must be preauthorized by TECH LINE or your dealership’s Technical Service & Parts Manager (TSPM) prior to submission. Long Claim Forms submitted without a PAS number will be returned, unpaid.
CAMPAIGN 3A01 GSX1300RM4 ABS HYDRAULIC UNIT FLARE NUT TIGHTENING
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:
3A01
LABOR TIME:
As authorized by your TSPM*
PARTS INFORMATION:
59400-10L00-RXO (HOSE ASSY UNIT FRBK)
Quantity 0
ADDITIONAL PARTS:
Additional parts as authorized by your TSPM**
AUTHORIZATION:
Only needed if additional parts or labor claimed
FAILURE DESCRIPTION:
DESCRIPTION OF DEFECT:
ABS hydraulic unit flare nut tightening
DESCRIPTION OF REPAIR:
Performed service campaign repair per service bulletin
Continued on the following page >>
* If using the Long Claim Form to request parts reimbursement, but not additional labor, use the labor code of MD9999 for 0.9 hour.
** If brake fluid was used, you will need to add the brake fluid part number (990A0-01E91-12Z) to the additional parts list.
4 / 19
Precautions: ●
Take care to not let grease or oil (mineral oil, etc.) contaminate the brake system. ●
When touching brake system components, keep your hands/work-gloves clean, and do not use tools contaminated with grease or oil (mineral oil, etc.). ●
Brake fluid can damage painted surfaces, plastics and rubber materials, so do not allow the fluid to spill on any portion of the motorcycle. ●
If brake fluid is spilled, flush it from the parts with water immediately. ●
This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. ●
Do not use DOT 5 or other silicone-based brake fluids. ●
Do not use or mix different types of brake fluid, such as silicone-based or petroleum-based. ●
Do not use any brake fluid taken from an old, used or unsealed containers. ●
Never reuse brake fluid left over from a prior service or that has been stored for a long period of time. ●
When replenishing brake fluid, take care to not let dust or other contaminates into the fluid. ●
To avoid getting burned, do not touch the engine and exhaust system until they have cooled. ●
Before the repair work, wash dirt off from the vehicle so that removed parts are kept free from dust. ●
When 2 or more persons work together, pay attention to each other’s safety. ●
When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
ABS HYDRAULIC UNIT FLARE NUT TIGHTENING RECALL SERVICE PROCEDURE ●
Follow the repair procedure listed on the following pages to tighten the brake fluid pipe flange nuts 1 on the ABS hydraulic unit to the proper torque.
Refer to the Hayabusa Service Manual (99500-10L00-03E) for
any details or procedures not mentioned in these instructions.
Continued on the following page >>
Chemical: Brake Fluid
Suzuki ECSTAR DOT 4 (990A0-01E91-12Z) ●
If brake fluid leakage is found, check the brake fluid level. And if the brake fluid level is below the lower limit line, replenish the brake fluid up to the specified amount. Clean any area contaminated by leaked or spilled brake fluid.
NOTE:
In the unusual instance you used enough brake fluid to warrant reimbursement from Suzuki, add the brake fluid (990A0-01E91-12Z) to a Long Form warranty claim. Before submission, you must obtain a pre-authorization number (PAS) from TECH-LINE or your TSPM, and then submit a Long Claim Form with a PAS number applied (see page 3 of this bulletin for more information).
5 / 19
Required tools:
Tool or item
Size or capability
Ratchet handle
(to match socket wrenches)
Socket wrench
10 mm
Hexagon wrench (Allen-wrench)
4 mm, 5 mm, 6 mm
Pliers
(as required)
Torque wrench
Range: 3.0 to 17.0 lb-ft
or (4.0 to 23 N.m) or (0.41 to 2.3 kgf-m)
Flare nut socket wrench 1
10 mm (11.5 lb-ft (1.63 N.m, 1.6 kgf-m)),
Drive hole to match the drive of the torque wrench
Continued on the following page >>
NOTE:
The flare nut socket wrench (example 1) is not the same as a crow’s foot wrench. The crow’s foot wrench has a driving head like a open wrench. A flare nut socket wrench has a closed-hex driving head with a small grove that allows it to pass over the pipe that is secured by a flare nut. This helps ensure that no slippage occurs between the tool and nut so the proper torque is applied to the flare nut during tightening.
If you install the flare nut socket wrench onto the drive head of the torque wrench at exactly 90-degrees (see image above) the torque value of the torque wrench will be accurate (in this case, 12.0 lb-ft (16 N·m, 1.6 kgf-m)).
If the flare nut socket wrench is not set exactly at 90-degrees on the torque wrench drive, a difference occurs between the set value of the torque wrench and the actual torque being applied. This occurs because of the distance (length) between the drive head of the torque wrench and wrench head of the flare nut wrench. Because this length affects the force of the torque applied to the flare nut you will need to calculate the torque setting for the torque wrench based upon the effective length of the flare nut socket and the torque wrench to be used.
Example:
Effective length of torque wrench: A mm
Effective length of flare nut socket: B mm
Specified torque: 12.0 lb-ft (16 N·m, 1.6 kgf-m)
In the above case, the set value is “12 × A ÷ (A + B)“.
Reminder:
When tightening the flare nuts, be sure to position the torque wrench and flare nut socket straight.
90O
6 / 19
ABS Hydraulic Unit Flare Nut
Tightening RECALL SERVICE Procedure:
Reference: GSX1300R Service Manual (99500-10L00-03E)
Fuel Tank Removal:
1.
Turn the ignition switch OFF.
2.
Remove the front seat bolts 1 and front seat 2.
Continued on the following page >>
NOTE:
During this repair you will remove the battery and when this is done the SDMS mode setting will revert to A mode and the engine RPM indicator light (shift light) will be deactivated. Additionally, the clock will need to be reset. When working on a customer’s Hayabusa note the SDMS and engine RPM indicator light settings so you can restore them when you reset the clock.
3.
Disconnect the battery negative (–) lead wire 3.
4.
Remove the plastic push-pin fasteners and bolt from the meter panel 4.
7 / 19
5.
Remove the meter panel 6 in the direction shown in the illustration so you will unhook the panel’s hooks.
Continued on the following page >>
6.
[Not shown] Remove the left side meter panel as shown in steps 4 and 5.
7.
Remove the fuel tank cap cover bolts and remove the fuel tank cap cover 2.
8.
Remove the hook, fasteners 3 and bolts as shown in the illustration.
8 / 19
Continued on the following page >>
9.
Unhook the side cowling assembly 2 from the locating pin 3 of the bracket.
10.
Remove the fuel tank front cover bolt 4.
11.
Pull the side cowling assembly 5 in the direction as shown in the illustration to make the space and remove the fastener 6
12.
[Not shown] Pull the left side cowling assembly and remove the fastener as you did in steps 8 through 11.
NOTE:
To prevent damage to frame, remove the clip nut 1 from the side cowling assembly.
9 / 19
Continued on the following page >>
13.
Unhook the hooks and disconnect the fasteners 1 to remove the fuel tank cover 2.
14.
Remove the fuel tank bolts 3 from the frame 4.
15.
[Not shown] Lift and support the fuel tank.
16.
Disconnect the fuel pump coupler 5 from the fuel tank.
17.
Place a clean, absorbent rag under the fuel feed hose 6.
18.
Pull the retainer 7 out.
19.
Disconnect the fuel feed hose joint 8 from the fuel pump.
20.
[With EVAP Control System] Disconnect the EVAP surge hose 9 and the fuel tank water drain hose AT from the fuel tank.
[Without EVAP Control System] Disconnect the fuel tank breather hose 9 and the fuel tank water drain hose AT from the fuel tank.
10 / 19
Continued on the following page >>
21.
Remove the fuel tank rear bracket bolts 1 and rear brake master cylinder reservoir tank bracket bolt 2.
22.
Lift up the rear end of the fuel tank, and them remove the fuel tank rear bolt 3 and the fuel tank 4.
NOTE:
[Not shown] Place the fuel tank 4 in a safe location so it will not be damaged.
23.
Remove the fuel tank rear spacer 5 from the fuel tank (so it will not get lost).
Brake Pipe Flare Nuts Tightening:
1.
Tighten the brake pipe flare nuts 1 to the specified torque.
Tightening torque:
Brake pipe flare nut (a): 11.5 lb-ft (16 N.m, 1.6 kgf-m)
NOTICE:
•
Make sure to hold the brake pipe when tightening the flare nut, or it may become misaligned.
•
Do not allow the torque wrench to contact with the surrounding pipe or other parts, when tightening the brake pipe flare nuts to the specified torque. Otherwise, the brake pipe flare nut may not tighten to the specified torque.
Brake Fluid Leakage Check:
1.
[Not shown] Check the around the brake pipe flare nuts to make sure there is no brake fluid leakage.
NOTE:
•
If brake fluid leaks, wash and clean away the fluid with water.
•
Check the brake fluid level. If the brake fluid level is below the lower limit line, replenish the brake fluid to the specified amount.
Chemical: Brake Fluid
Suzuki ECSTAR DOT 4 (990A0-01E91-12Z)
11 / 19
Continued on the following page >>
Fuel Tank Installation:
Install the fuel tank in the reverse order of removal. Pay attention to the following points:
1.
Attach the fuel tank rear bolt spacer 1 to the fuel tank.
2.
Tighten the fuel tank rear bolt 2 to the specified torque.
NOTICE:
•
Be sure not to bend or twist the hoses when installing the fuel tank.
Tightening torque:
Fuel tank rear bolt (a): 7.5 lb-ft (10 N.m, 1.0 kgf-m)
3.
Tighten the fuel tank’s rear bracket bolts 3 and the rear brake master cylinder reservoir tank bracket bolt 4 to the specified torque.
Tightening torque:
Fuel tank rear bracket rear bolt (b): 7.5 lb-ft
(10 N.m, 1.0 kgf-m)
Tightening torque:
Rear brake master cylinder reservoir tank bracket bolt (c): 7.5 lb-ft (10 N.m, 1.0 kgf-m)
4.
Connect the fuel pump coupler 3 to the fuel pump; press it in and confirm that it “clicks” into place.
5.
Connect the fuel feed hose joint 4 to the fuel pump.
6.
Press in the retainer 5 to lock it to the fuel feed hose joint 6.
7.
[With EVAP Control System] Connect the EVAP surge hose 7 and the fuel tank water drain hose 5 to the fuel tank.
[Without EVAP Control System] Connect the fuel tank breather hose 7 and the fuel tank water drain hose 8 to the fuel tank.
NOTE:
•
Position the surge hose so the white mark on the hose faces the left side (of the motorcycle).
•
Position the fuel tank water drain hose so the white mark on the hose faces the front (of the motorcycle).
12 / 19
Continued on the following page >>
8.
Remove the absorbent rag.
9.
Tighten the fuel tank bolts 1 to the specified torque.
10.
Install the fuel tank cover and tighten the fuel tank cover bolt 3 to the specified torque.
NOTICE:
•
When installing the fuel tank, use care to not pinch the throttle cables 2.
Tightening torque:
Fuel tank front bolt (a): 4.05 lb-ft 5.50 N.m, 0.56 kgf-m)
11.
Pull the side cowling assembly 4 in the direction shown in the illustration to create the necessary space and install the fastener 5.
Tightening torque:
Fuel tank front cover bolt (b): 2.95 lb-ft
(4.0 N.m, 0.41 kgf-m)
NOTICE:
•
Do not pull the side cowling assembly too far away from the motorcycle as it may damage the side cowling assembly.
NOTE:
•
Use care to not drop or misplace the fastener 5.
12.
Attach the removed clip nut 6 to the side cowling assembly 7.
13.
Hook the side cowling assembly 8 to the locating pin 9 of the bracket.
13 / 19
Continued on the following page >>
14.
Tighten the under cowling bolt 1 and side cowling assembly bolt 2 to the specified torque.
Tightening torque:
Under cowling bolt (a): 4.05 lb-ft (5.50 N.m, 0.56 kgf-m)
15.
[Not shown] Perform the reinstallation of the left side cowling assembly as shown in steps 10 through 14.
16.
Install the fuel tank cap cover 3 and install and then tighten the fuel tank cap cover bolts 4 to the specified torque.
Tightening torque:
Side cowling assembly bolt (b): 4.05 lb-ft
(5.50 N.m, 0.56 kgf-m)
17.
Install the meter panel 5 in the direction shown in the illustrations so you will engage the panel’s hooks.
Tightening torque:
Fuel tank cap cover bolts (c): 4.05 lb-ft
(5.50 N.m, 0.56 kgf-m)
14 / 19
Continued on the following page >>
18.
Install the fasteners 1 and meter panel bolt 2 to the meter panel 3, and then tighten the meter panel bolt 2 to the specified torque.
(a)
19.
[Not shown] Install the left side meter panel as in shown in steps 17 and 18.
Tightening torque:
Meter panel bolt (a): 2.95 lb-ft (4.0 N.m, 0.41 kgf-m)
20.
Connect the battery negative (–) terminal 4.
21.
Slide the front seat 5 into bracket and tighten the front seat bolts 6 to the specified torque
Tightening torque:
Front seat bolt (b): 17.0 lb-ft (23 N.m, 2.3 kgf-m)
NOTE:
•
Align the front seat tab hole 7 with the threaded hole 8 in the frame.
•
Verify that the cushion 9 has not been distorted or pushed off the seat tab before inserting the seat bolt 6 into the seat tab hole.
15 / 19
Continued on the following page >>
1.
Verify that you did not leave tools or other objects (like shop rags) within the body of the motorcycle.
2.
Check that each part that was removed is reinstalled to its proper place and is securely fastened to the motorcycle.
3.
Check that there is no fluid or grease residue on any part of the motorcycle (excluding components where a lubricating grease is specified).
4.
If you squeeze the front brake lever, or press down on the rear brake pedal, and the response feels soft when you squeeze it, inspect the brake system to see if any air is trapped within the brake fluid. Resolve any issues; examine the brake fluid and bleed the air out of it until the lever and pedal action feels firm.
Final check:
If you have any questions related to this recall service, please call TECH-LINE at (714) 996-7480 or contact your Technical Service & Parts Manager (TSPM).
Thank you for your attention to this recall service,
The Suzuki Service Department
NOTE:
•
For brake fluid service and bleeding, see section 4 of the Hayabusa Service Manual.
•
If you experience difficulty bleeding air from the brake system, you can use your dealership’s SDS-II Diagnostic Tool to perform to operate the ABS pump motor to help purge air from the brake fluid in the Hydraulic Unit Assembly. See Service Bulletin – Tools No. 119 for more information.
5.
Set the instrument panel’s clock to the proper date and time (Reference: Owner’s Manual).
6.
On a customer-owned Hayabusa, restore the SDMS and Engine RPM Light (Shift Light) setting to the customer’s original setting (Reference: Owner’s Manual).
7.
If the brakes and other pre-ride inspection indicates the motorcycle is safe to operate, test ride the motorcycle on a dry road surface and operate the front and rear brakes independently to verify the function is normal. Additionally, check for any unusual sounds and that all controls operate properly.
Hayabusa Service Manual
99500-10L00-03E
2024 Hayabusa Owners Manual
99011-10L20-03A
Both publications are available on Suzuki CONNECT Technical Library (Technical Manuals menu).
REMINDER:
•
Before delivery to the customer, make sure the motorcycle is clean and free of finger prints. Thank your Hayabusa customers for their patience as you performed this recall service.
16 / 19
SALES BULLETIN 24-012, STOP SALES HAYABUSA (page 1 of 2)
Continued on the following page >>
17 / 19
SALES BULLETIN 24-012, STOP SALES HAYABUSA (page 2 of 2)
Continued on the following page >>
18 / 19
CUSTOMER NOTIFICATION LETTER (page 1 of 2)
Continued on the following page >>
February 5, 2024February 2024
19 / 19
CUSTOMER NOTIFICATION LETTER (page 2 of 2)
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CONFIDENTIAL
Motorcycle Service Group Overseas Service Department
8686 Miyakoda-cho, Hamana-ku, Hamamatsu-shi, Shizuoka, Japan 431-2102 Tel: 81-53-528-8118, Fax: 81-53-528-8141
TO: Suzuki Motorcycle Distributors ATTN.: Managing Director
Service Manager
SUBJECT: GSX1300R(Hayabusa) ABS Hydraulic Unit Flare Nut Tightening Recall
Campaign
Dear Sirs and Madams, This letter is to inform you of the “ABS Hydraulic Unit Flare Nut Tightening Recall Campaign” for GSX1300RRQM4 and GSX1300RRQ2M4(Hayabusa) produced from Jul. 7, 2023 to Dec. 1, 2023. We were informed from our production plant that in the piping of the brake system, the tightening torque of the flare nut for fastening the brake pipe to the ABS unit may insufficient due to improper tightening work of the nut. If the motorcycle continues to be used in this condition, in the worst case, the loosening of the nut may cause brake fluid leakage and increase the braking distance. 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, Shinji Ishikawa
Department General Manager Overseas Service Department Suzuki Motor Corporation Page 1 of 3 Date Jan. 26, 2024
Our ref. JE-240118A-R1
Revised Page 2 of 3 Action
For the affected units before retail sales, you are requested to remedy them before delivering them to the customers.
1) Check stock status
2) Confirm repair work procedure
3) Perform a repair work
4) Report completion to SMC with ANNEX2 VIN list of stock units.
For the affected units after retail sales, contact the customers of the units to let them bring their vehicles to your authorized dealers.
1) Check status of affected units
2) Report to the authority according to your law.
3) Issue service bulletin to dealers and customer letter to owners.
4) Perform a corrective work following the repair instruction of ANNEX3. Affected Models
Model: GSX1300RRQM4, GSX1300RRQ2M4(Hayabusa)
Production Period: From Jul. 7, 2023 to Dec. 1, 2023
Affected VIN range and units quantity in your market: Please refer to attached VIN list of ANNEX2.
Please fill “Completion date” in ANNEX2 Sheet ”Stock”, and send it back to us after you complete the work. Replacement Parts
Replacement Parts are not necessary for this campaign. 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. Revised Claim category Trouble Code Basic code 2 (Campaign) 97-JE JL MD9999 Model
GSX1300RRQM4, GSX1300RRQ2M4 Part Name HOSE ASSY,UNIT TO FR
BK CLPR Part No.
59400-10L00 Q’ty 0 Flat Rate(Hr) 0.9 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: “GSX1300R_Repair_Instruction_of_Tightening_ABS_Hydraulic_Unit_Flare_ Nuts.doc” Implementation Date and Progress
1) Implementation Date:
Please fill following planning schedule in the Microsoft Forms (Link of the webpage) or ANNEX1 (Excel file) and send back to us by January. 31, 2024.
(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) Recall campaign notification date to distributor if you have resold affected unit to other distributor.
Please fill following latest information in the Microsoft Forms (Link of the webpage) or ANNEX1 (Excel file) and send back 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) Recall campaign notification date to distributor if you have resold affected unit to other distributor. 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 units.
(3) Updated number of affected units, if adjusted. Attachment:
ANNEX 1: Recall_campaign_notification_plan_form.xlsx
ANNEX 2: Country_Name_VIN_List.xlsx
ANNEX 3: GSX1300R_Repair_Instruction_of_Tightening_ABS_Hydraulic_Unit_Flare_ Nuts.doc ANNEX 4: Sample_Of_Customer_Letter
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SEOCONTENT-END