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2003-2004 HONDA GL 1800/A Frame Weld Safety Recall

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Filed Under (Honda) by admin on 15-12-2010

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there is no punch mark on the VIN plate as specified in this Service Bulletin, proceed to the REPAIR PROCEDURE section of this Service Bulletin. IMPORTANT: Due to the complexity of this campaign it is imperative that you check iN and your Dealer Responsibility Report before you begin repairs. If iN or your Dealer Responsibility Report indicate the Safety Recall has been performed, but you confirm the unit is not punched and the repair has actually been done (by inspecting the weld), please contact the Warranty HelpLine at (800) 421-1900, option 7. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510)  Frame Weld Inspection Chart (S0516) You MUST provide your TIG welder with the following items:  2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511)  2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) Welding Template Box (S0512) All of the above items were shipped to you with Service Bulletin GL1800 #14. If you need additional copies of these materials, you may order them from Resolve at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. DISASSEMBLY OVERVIEW You will be removing the following components from the vehicle as instructed in the Dealer Booklet : Handlebar weights Rear view mirrors Swingarm pivot covers Rider foot pegs Seat Side covers/Engine side covers Fairing pockets Fairing molding Meter panel Top shelter Battery Fuel tank Main wiring harness ground Front lower fairing Front exhaust pipe protector Muffler/exhaust pipe Antenna Whip(s) Coolant reserve tank Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: Before you send the motorcycle to the welder, you MUST check for lower crossmember frame weld cracks.  If your inspection reveals no cracks in or on either the Left or Right lower cross- member frame welds, proceed to the REPAIR PROCEDURE OVERVIEW section of this Service Bulletin.  If your inspection identifies a crack or cracks in or on either the Left or Right lower crossmember frame welds, perform the following procedure: Place the grinding template (S0512) on the crossmember. Using a suitable felt marker, draw a line on the weld with the crack, drawing the line along the entire edge of the the template (this line will be 89 mm long). If the crack falls within the length of this line (89 mm) , prepare the motorcycle for welding per the Dealer Procedures and advise the welder to use the Cracked Weld Repair Manual (S0515). After the bike has returned from the welder, prepare the frame and re-assemble the motorcycle per the Dealer Procedures . Then, proceed

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YAMAHA MOTOR CORPORATION, U.S.A. STREET & ENDURO MOTORCYCLE LIMITED WARRANTY

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Filed Under (Yamaha) by admin on 27-12-2011

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GENERALEXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. Areasonable dealer imposed fee may be charged for the inspection. In no case will warranty be extended beyond the original period. EMISSIONS CONTROLSYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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2001-2002 Honda GL1800/A Frame Weld Inspection PROCEDURE

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Filed Under (Honda) by admin on 22-04-2011

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IMPORTANT: During these procedures you may be using and referring to the following materials, originally sent to you with Service Bulletin GL1800 #14. • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Procedures (S0510) • Frame Weld Inspection Chart (S0516) • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • 2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) • Welding Template Box (S0512)If you need additional copies of these materi- als you may order them at no cost from Resolve at (440) 572-0725. 1. Position the motorcycle on a firm, level surface, in an area where there is enough room to safely lay it on its left side. 2. Remove the left side mirror by following the nstructions on page 2-7 of the Service Manual. 3. Remove the left engine side cover by following the nstructions on page 2-5 of the Service Manual. 4. Remove the antenna whip(s). 5. Remove the coolant reserve tank by fol- lowing the instructions on page 6-7 of the Service Manual. 6. Place thick, non-abrasive padding (such as furniture blankets) on the ground to protect the motorcycle when you lay it on its side. 7. Lock the handlebars to the RIGHT, using the ignition key. 8. Using two people, gently lay the motor- cycle down on its LEFT side on the pad- ding. The motorcycle will first rest on the wheels and left engine and saddlebag guards. Continue to lean the motorcycle to the left until it rests on the left handlebar end and left engine and saddlebag guards. The motorcycle should be laying on the padding, with its engine guard, saddlebag guard, and handlebar end resting on the padding – no painted parts should be con- tacting the padding. 9. Clean the frame crossmember with acetone. 10. Draw a line on each side of the grinding template (S0512) 30 mm from the for- ward edge, stopping  between the two arrows, as illustrated below. 11. Put this template on the frame and, using a fine-tipped felt marker (such as a Sharpie), draw a 30 mm line on both crossmember welds. Start this line at the forward edge of the grinding template and stop between the two arrows as shown in the illustration on the next page.Now remove the grinding template

HARLEY DAVIDSON STREAMLINER FOOTPEG KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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NORMAL TOOTH WARRANTY This extended warranty applies only to the normal wear that will occur to the tooth profile geometry on the rear belt sprocket. Normal wear is considered wear that occurs when the protective hard coating has worn away exposing the underlying aluminum, changing the profile of the sprocket tooth significantly. Warranty is for five years from date of purchase with unlimited mileage. Warranty claims will require a dated receipt showing proof of purchase from an authorized Harley-Davidson Dealer. Warranty only applies to original purchaser of the sprocket. Original owners name must appear on the receipt. All applications of the sprocket require installation of upper and lower original equipment belt guard, or Harley-Davidson accessory belt guards where applicable. Warranty is voided if these items are not installed. Excessive chips found in the tooth profile due to abnormal riding conditions will void warranty. Occasional chips in the tooth are to be considered normal and should not be considered a warranty issue. Decorative external chrome carries the standard parts and accessories 90 day warranty. Staking the flange on the backside of the sprocket will pierce through the chrome, this is to be considered a normal process and should not be considered an issue. All warranty claims must be pursued through your authorized Harley-Davidson Dealer

HARLEY DAVIDSON SOFTAIL SPROCKET KIT INSTALLATION NOTES

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Filed Under (Harley Davidson) by admin on 29-01-2011

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NORMAL TOOTH WARRANTY This extended warranty applies only to the normal wear that will occur to the tooth profile geometry on the rear belt sprocket. Normal wear is considered wear that occurs when the protective hard coating has worn away exposing the underlying aluminum, changing the profile of the sprocket tooth significantly. Warranty is for five years from date of purchase with unlimited mileage. Warranty claims will require a dated receipt showing proof of purchase from an authorized Harley-Davidson Dealer. Warranty only applies to original purchaser of the sprocket. Original owners name must appear on the receipt. All applications of the sprocket require installation of upper and lower original equipment belt guard, or Harley-Davidson accessory belt guards where applicable. Warranty is voided if these items are not installed. Excessive chips found in the tooth profile due to abnormal riding conditions will void warranty. Occasional chips in the tooth are to be considered normal and should not be considered a warranty issue. Decorative external chrome carries the standard parts and accessories 90 day warranty. Staking the flange on the backside of the sprocket will pierce through the chrome, this is to be considered a normal process and should not be considered an issue. All warranty claims must be pursued through your authorized Harley-Davidson Dealer

YAMAHAMOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY

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Filed Under (Yamaha) by admin on 26-11-2010

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any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and

HONDA 2002-2004 GL1800/A Linked Braking System (LBS) Proportional Control Valve (PCV) Leakage

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Filed Under (Honda) by admin on 25-11-2010

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1. Pump the rear brake pedal four times. •If the brake pedal feels spongy, bleed the brake system per the Service Manual. After verifying proper brake system operation, proceed to step 2 below. •If the brake pedal does not feel spongy, proceed to step 2 below. 2. Place the motorcycle on its side stand, with the handlebars in the full left position . Lock the handlebars. 3. Place a scissor jack directly under the left front brake caliper as shown in the illustration. To avoid damage to the caliper, place a protective piece of rubber (such as a piece of inner tube) between the caliper and the jack. Wind up the jack until the front wheel is approximately 15 mm off the ground. 4. Measure the distance from the secondary master cylinder piston mounting bolt to the edge of the secondary master cylinder body (rod length of the secondary master cylinder). Record this measurement . • If the measured length is 30.3 mm, replace the PCV per the Service Manual. (This length indicates the unit’s secondary master cylinder is fully stroked, which means there is no hydraulic brake pressure acting on the PCV.) After replacing the PCV, proceed to the IDENTIFICATION section of this Service Bulletin. •If the measured length is longer than 30.3 mm , proceed to step 5 below. • INSPECTION/REPAIR PROCEDURE Record this measurement. Pump the rear brake pedal four times.
GL1800/A #16 ©2005 American Honda Motor Co., Inc. – All Rights Reserved 3 of 6 FEBRUARY 2005 5. Wait 30 minutes. Do not disturb the motorcycle in any way during this time. 6. Measure the distance again from the secondary master cylinder piston mounting bolt to the edge of the secondary master cylinder body (rod length of the secondary master cylinder). •If the measurement has decreased more than 1 mm from the measurement you recorded, proceed to step 7 below. •If the measurement is within 1 mm of the measurement you recorded, the PCV is OK. Proceed to the IDENTIFICATION section of this Service Bulletin. 7. Check the PCV for leakage. • If the PCV is leaking , replace the PCV per the Service Manual. After replacing the PCV, proceed to the IDENTIFICATION section of this Service Bulletin. • If the PCV is not leaking , you must diagnose the brake system problem before proceeding. After you have diagnosed and repaired the brake system, proceed to the IDENTIFICATION section of this Service Bulletin. NOTE: Any brake system problem not related to the PCV that is found while performing this Service Bulletin is not covered by this Safety Recall. If the motorcycle’s original factory warranty is still in effect or under HPP, file a normal warranty claim. If the unit is outside its factory warranty period or HPP coverage, contact TechLine for goodwill consideration. 8. Verify proper front and rear brake operation by pumping the front brake lever and rear brake pedal before riding the motorcycle

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2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

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2009 Honda CRF450R Decompression Plunger PRODUCT UPDATE CAMPAIGN

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Filed Under (Honda) by admin on 21-04-2011

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JH2PE053*9K700001 thru JH2PE053*9K703372 (*) Denotes check digit UPDATE PROCEDURE DEALER VENTORY Any affected unit in your inventory must be updated with a new decompression plunger and weight before delivery to the customer. Refer tothe PARTS INFORMATION and the UPDATE PROCEDURE sections of thisb Service Bulletin. Refer to the 2009 CRF450R Service Manual for specific removal instructions. 1. Remove the seat (page 3-3). 2. Remove the shrouds (page 3-4). 3. Properly hang the fuel tank (page 4-6). 4. Remove the camshaft (page 9-10) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. 5. Replace the decompression weight and plunger with kit parts (page 9-14). 6. Reinstall all previously removed parts. IDENTIFICATION When you have completed the update, place a punch mark before the first digit of the V.I.N. located on the right side of the steering head. 0080 WARRANTY INFORMATION This Product Update Campaign ends on arch 7, 2012. Normal claim submission requirements apply. fter completing the UPDATE PROCEDURE,submit one warranty claim per unit with the following information: WARRANTY CLAIM TEMPLATE: Template: R02A* Flat Rate Time: 1.2 hours *Template reads “R-zero-2-A”.

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