Ballerup, den 19. januar 2016 Recall information fra C. Reinhardt Kære alle Vi har modtaget en recall fra Suzuki Global. I dette brev kan du læse de vigtigste punkter vedrørende problemerne og hvordan du udbedrer det for dine kunder. Recall en vedrører; DL1000AL4. L5, L6 Ignition Switch Coupler. Wiring Harness and Ground Wire. For at udbedre problemerne skal du gøre følgende: 1. Kontakt din kunde og få MC ind på værkstedet, udfør kontrol i henhold til vedhæftet filer fra Japan 2. Stelnummerliste vedhæftet 3. Bestil de dele der skal bruges 4. Indsend reklamation online Hvis du har spørgsmål til denne recall, er du altid velkommen til at kontakte serviceafdelingen på telefon 44 83 09 30. Info fra Suzuki Japan at der kan forekomme korrosion i tændingslås ledningsnet og stelledning Alt materiale hvorledes i som forhandler skal forholde jer er udsendt på mail til alle Suzuki MC Forhandler Læs det godt igennem og bestil de dele i skal bruge ud fra de oplyste reservedeles nummer. De berørte DL1000 i Danmark gælder kun årgang 2014 og årgang 2015 Fra stel nummer JS1DD111100105172 til stelnummer i JS1DD111100109278 Alle Suzuki MC forhandler får tilsendt mail direkte fra CR, på de stelnummer i har solgt via af jeres butik Arbejds beskrivelse findes på side 5. 1
KOPI AF BREV FRA SUZUKI GLOBAL Subject : DL1000Al4. L5, L6 Ignition Switch Coupler. Wiring Harness and Ground Wire Recall Campaign This letter is to inform you of the "Ignition Switch Coupler, Wiring Harness and Ground Wire Recall Campaign" for DL1000AL4, L5, L6 produced from November, 2013 to 15 July 2015 There are three (3) kinds of the problem as follows. 1. Ignition Switch Coupler 1.Ignition switch The ignition switch connector is splashed with a corrosive liquid such as antifreeze or saltwater, the terminals can corrode. If the corrosion progresses, the ignition lead wire and wire harness terminals of the connector can be connected, completing the power circuit independent of the ignition switch. Under this condition, the engine cannot be stopped by turning off the ignition key. The corrosion can also lead to disconnection of electrical power. 2.Wiring Harness Wiring harness may contact the bottom of the fuel tank due to improper design of its routing. If motorcycle is kept using under above condition, it may cause wiring harness insulation wear and cause poor engine running in case of wiring harness makes short circuit. In the worst case, the engine stops during motorcycle running. 3.Ground Wire Battery earth may cause poor electric continuity due to improper fixing position of it during usage. If motorcycle is kept using, it may cause no engine starting due to no starter motor working in the worst case. Affected Models Model: DL1000AL4, L5, L6 Production Period: 1. Ignition Switch Coupler: Produced from November 1, 2013 to March 31, 2015. 2. Wiring Harness: Produced from November 1, 2013 to July 15, 2015. 3. Ground Wire : Produced from November 1, 2013 to May 26, 2015. Note: Depending on the production date, the numbers of required repair works differ as shown in the table below. 2
Necessary repair Work Production period 1. Ignition Switch Coupler 2. Wiring Harness 3. Ground Wire From November 1, 2013 to March 31, 2015 YES YES YES From April 1, 2015 to May 26, 2015 No need YES YES From May 27, 2015 to July 15, 2015 No need YES NO Need Replacement Parts It is necessary to select a replacement parts "Set A" or "Set B" according to the inspection results. For the inspection details, refer to the repair instructions. Result of inspection Ignition switch coupler terminal is not corroded; lead wire insulator is not worn or without exposure of conductors in spite of insulator wear. Ignition switch coupler terminal is corroded or lead wire insulator is worn and conductors are exposed. Replacement Parts "Set A" Estimated rate is about 80%. "Set B" Estimated rate is about 20%. 3
Note: It is necessary the special tool (37199-31J00-RX0) to replace Ignition switch lead assembly of "Set B". If you don't have this tool, please order it. Please order the necessary number of parts at C. Reinhardt as parts department 1. Replacement parts "Set A" Part name Part number Quantity Contents Harness tape 36611-31J00 x 1 Coupler cover 36618-31J10 x 1 Clamp 09407-19401 x 1 Set A 36600-31810-RX0 1 Abrasion proof tape 48599-57L00 x 1 Clamp 09407-14407 x 1 Coupler set 36611-31J10 x 1 Heatproof tube 33816-31J00 x 1 Abrasion proof tube 33816-31J10 x 1 For E21 spec. Part name Part number Quantity Contents Ignition switch lead assembly 37150-31JOO x 1 Wire harness 36610-31J60 x 1 Set B 36600-31830-RXO 1 Clamp 09407-14407 x 5 Clamp 09407-17403 x 1 Abrasion proof tape 48599-57LOO x 1 Heatproof tube 33816-31JOO x 1 Abrasion proof tube 33816-31J10 x 1 4
Explanation for Modification Points Inspect terminals in the ignition switch coupler for the corrosion and the lead wires at the branch section (IAP sensor #1, #2 / IAT sensor / STP sensor lead wires) for abrasion. If any abnormality is found, replace the wire harness with the countermeasure harness. Change clamping position of the ground wire terminal and add the protection tube. The repair method varies according to the check result with the flow chart. Branch section Ignition switch coupler 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 motorcycle 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. When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. Refer to the service manual for the details not mentioned in the instructions. 1 Ground wire terminal
1-2. Ignition Switch Coupler / Wire Harness / Ground wire Inspection and Replacement Perform necessary job according to the following flow chart. -1 Preparation for Inspection Use of Set B -2 Check of Ignition Switch Coupler for Corrosion Corroded -5 Ignition Switch Lead Wire Replacement -6 Wire Harness Replacement Not corroded -3 Check of Wire harness (IAP sensor #1, #2/IAT sensor/stp sensor lead wires) for Abrasion Use of Set A Not abrasion Abrasion Conductors exposed Use of Set B -5 Ignition Switch Lead Wire Replacement -6 Wire Harness Replacement -4 Ignition Switch Coupler Cover Installation Conductors not exposed Use of Set A -4 Ignition Switch Coupler Cover Installation -8 Protection of Lead Wire Worn Part by Taping -9 Countermeasure of Wire harness Routing -9 Countermeasure of Wire harness Routing -10 Change of Ground Wire Terminal Position -11 Reinstallation of Removed Parts 5