990135 – Front Brake Hose May Leak – 2019 Yamaha YZF-R3 Motorcycles

February 10, 2020 NHTSA CAMPAIGN NUMBER: 20V071000

Front Brake Hose May Leak

A brake fluid leak can reduce braking ability, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V071

Manufacturer Yamaha Motor Corporation, USA

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 1,561

 

Summary

Yamaha Motor Corporation, USA (Yamaha) is recalling certain 2019 YZF-R3 motorcycles. The front brake hose my chafe against the horn lead wire when the handlebars are turned from left to right, potentially resulting in a brake fluid leak.

 

Remedy

Yamaha will notify owners, and dealers will inspect the front brake hose, replacing it as necessary, and reroute the horn lead wire, free of charge. The recall began February 28, 2020. Owners may contact Yamaha customer service at 1-800-962-7926. Yamaha’s number for this recall is 990135.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check for Yamaha Recalls

 

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MOTORCYCLE

2/28/2020

M2020-002R

 

SAFETY RECALL

This modification has top priority. This bulletin must be performed  immediately to ensure customer safety. NOTE: Bulletins that announce a recall will have an “R” at the end of the bulletin number.

 

CERTAIN 2019 YZFR3AK (YZF-R3 ABS) MODELS

FACTORY MODIFICATION CAMPAIGN – Brake Hose Holder Comes Off

 

INTRODUCTION

Yamaha Motor Corporation, U.S.A. has decided that a defect which relates to motor vehicle safety exists in certain 2019 YZFR3AK (YZF-R3 ABS) motorcycles. In affected units, the brake hose holder may come off the front fork bracket due to an incorrect bracket hook shape. As a result, this could allow the hose protector cover to touch the front fork tube and cause wear to the cover. A worn cover could expose the brake hose to wear, causing it to leak brake fluid and affect braking ability, which could cause a crash with injury or death.

To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the brake hose inspected for damage or wear and replaced, if necessary, and the brake hose holder replaced with one that has the correct bracket hook shape.

Yamaha is notifying all registered owners of affected motorcycles by U.S. mail. A copy of this letter is included in this bulletin.

The customer should take this letter along with the affected motorcycle to an authorized Yamaha dealer for modification.

If your dealership was invoiced for one or more affected units, a computer report listing all affected motorcycles invoiced to your dealership is mailed with this bulletin. Use the list to help ensure all affected motorcycles are modified. All sold motorcycles that have been registered with Yamaha will show the customer’s name and address.

You must modify all affected motorcycles in your inventory as well as all customer-owned motorcycles brought to you for this service. If you purchase a motorcycle from another dealer or Yamaha, check to see if the procedures in this bulletin have already been performed before you sell the motorcycle.

Motorcycles that are affected should not be operated until they are modified. It is a violation of Yamaha policy for your dealership to deliver any affected motorcycle to customers until the procedures in this bulletin are performed.

When the modification on each motorcycle is performed, follow the Warranty Information section of this bulletin to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in Chapter 7 of the Warranty and Y.E.S. Handbook (LIT-11760-00-16).

 

DEALER ACTION SUMMARY

Unsold & Sold Units:	Use YDS Unit Status to check to be sure the unit is affected and that it is not already modified. If the brake hose holder is missing, inspect the brake hose protector and brake hose for wear or damage and replace the brake hose if necessary. Then, on all affected units, replace brake hose holders 3 and 4 with new ones from the modification kit.
Parts:	Yes. Order a brake hose holder. See the Parts Information section.
Warranty:	Factory Modification Campaign. See the Warranty Information section of this bulletin. This modification applies to all affected units regardless of ownership or warranty status.
Notify Customers:	Yes, you must immediately contact any customer if a motorcycle shows as unregistered on the enclosed report. Yamaha has sent letters to customers whose motorcycles were registered with Yamaha as of 2/27/2020.

 

IMPORTANT:

This recall is being announced at the same time as Technical Bulletin M2020-001R regarding Front Brake Hose Wear from Horn Wire Contact. If you are modifying a unit by both campaigns, be sure to perform both modifications at the same time for efficiency and customer satisfaction.

 

AFFECTED RANGE

Model	Model Year		Primary ID
		Prefix	From	To
YZFR3AK	2019	RH18Y	0001001	0002480

 

SERVICE PROCEDURES

A. Brake Hose Inspection

 

1. Check the brake hose holder is missing. If so, check the brake hose protector thoroughly for wear or damage.

If there is no wear or damage, replace the front brake hose holder.

If there is damage, refer to the service manual (p/n LIT-11616-32-26) to replace the brake hose before beginning this modification. Remember to check for wear from the horn lead wire per Technical Bulletin M2020-001R at the same time.

See the Warranty Information section for instructions on submitting a separate claim for brake hose replacement.

 

B. Replace Front Brake Hose Holder

1. To prevent damage, please cover the front fender.
2. Remove the brake hose clamp (1) next to the reflector. The clamp will be reused.

Remove the projection from the front of the

3. Remove the front brake hose holder nut (2) and remove the brake hose holders (3) and (4).
4. In reverse order of removal, replace brake hose holders (3) and (4) with new ones. included in the modification kit. Be sure to hook the tab of the holder (4) and the window of holder (3).
5. Attach the brake hose holders (3) and (4) assembled in the reflector bracket (5). Hook the holder (4) on the projection of the reflector bracket. Be sure the holder (4) is flush against the relfector bracket tab (5).
6. Install the brake hose holder nut (2) and tighten to the specified torque of 5 – 7Nm (0.65 ~ 0.70 m-kg, 4.8 ~ 5.2 lb-ft).
7. Clamp the brake hose (6) and install the projection of the clamp (5) to the hole of the reflector bracket (1).

 

IDENTIFICATION PROCEDURE

After inspecting or inspecting and modifying a unit, make sure to properly record and submit the special warranty claim for this safety recall to ensure correct reimbursement and to update the unit’s repair history in Yamaha’s database.

 

PARTS INFORMATION

Order a modification kit for each affected unit:

PART NUMBER	DESCRIPTION	QTY	DEALER COST
90891-20404-00	YZFR3 Brake Hose Holder Kit Contains: Holder, Brake Hose 3 (B5L-F5887-00-00) Holder, Brake Hose 4 (B5L-F587A-00-00)	1	$3.80

 

Brake Hose Components (ONLY if hose is damaged)

PART NUMBER	DESCRIPTION	QTY	DEALER COST
B5L-F581J-00-00	HOSE, BRAKE 4	1	$54.73
90201-10118-00	WASHER, PLAIN	4	$1.55 ea.
ACC-BRAKE-FL-UD	BRAKE FLUID 8 OZ	1	$4.75

 

WARRANTY INFORMATION

The owner of each registered motorcycle will receive a letter announcing this campaign. The customer’s letter includes the unit’s VIN and Recall Number.

The modification is authorized for all affected motorcycles, both sold and unsold, regardless of ownership or warranty status. You do not need the customer’s letter to perform the modification or to file for reimbursement.

Submit a Recall Claim for bracket replacement as described below using Campaign Number 990134. The labor allowance is 0.2 hours for the modification. If you had to replace the brake hose(s), refer to “Hose Replacement Claim” below.

 

YDS:

To submit your Recall Claim in the warranty system on YDS, go to Service > Warranty Claims / Authorization > Claims / Authorization > New > Warranty Claim. Then, from the menu, select Recall / Service per Bulletin Claim.

 

Hose Replacement Claim:

If the brake hose had to be replaced due to wear on the brake hose protector or brake hose itself, submit a separate Warranty Authorization Request for the hose replacement. The labor allowance is 0.7 hours.

If you have any questions about proper procedures for Factory Modification Campaigns, see Chapter 7 in your Warranty and Y.E.S. Handbook (LIT-11760-00-16).

 

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IMPORTANT SAFETY RECALL NOTICE

This notice applies to your vehicle, VIN   Model:

February 28, 2020

 

990135

 

Dear Yamaha Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Yamaha Motor Corporation, U.S.A. has decided that a defect which relates to motor vehicle safety exists in certain 2019 YZFR3AK (YZF-R3 ABS) motorcycles. Our records indicate that you own the affected motorcycle shown above.

 

The reason for this recall:	In affected units, the front brake hose can touch the horn lead wire when turning the handlebar from left to right. As a result, this could cause wear to the front brake hose, causing it to leak brake fluid and affect braking ability, which could cause a crash with injury or death.
What Yamaha and your dealer will do:	To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the brake hose inspected for damage or wear and replaced, if necessary, and then the horn lead wire rerouted. The procedure takes about 12 minutes to do. Be aware that your Yamaha dealer may need to keep your motorcycle longer. If the brake hose also requires replacement due to wear or damage due to the defect, the replacement procedure will take about another 45 minutes. There will be no charge to you for this procedure.
What you should do now:	Please call your Yamaha dealer to make a service appointment to have the procedure(s) performed. At that same time, you can find out how long they expect to keep your motorcycle to complete this service. Remember to take this letter with you when you take in your motorcycle. Only ride your motorcycle to the dealership to be repaired. You should avoid riding your affected motorcycle shown above whenever possible until you can get it to the dealer to have this modification performed. If you are unable to return to the Yamaha dealer who sold you the motorcycle, this service will be performed by any authorized Yamaha motorcycle dealer. To find a dealer near you, call 1-800-88-YAMAHA or visit the Yamaha website at www.yamaha-motor.com. If you have had this repair performed before you received this letter, you may be entitled to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this repair. For more information, contact Yamaha Customer Relations at 1-800-962-7926. Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within 10 days.
If you need help:	If, after contacting your dealership, you have questions or concerns which the dealership is unable to answer, please write to: Yamaha Motor Corporation, U.S.A. Customer Relations Department P.O. Box 6555 Cypress, CA 90630 Or call: 1-800-962-7926 If, after contacting Yamaha Customer Relations, you are still not satisfied that we have done our best to remedy the situation without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Auto Safety Hotline at 1-888327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov. Refer to NHTSA recall number 20V-071.
If you no longer own this Yamaha:	If you have sold your motorcycle to another party, please call us toll-free at 1-800-962-7926 with the name and address of the new owner, along with the serial number shown above your name on the address label above.

 

We’re sorry to cause you any inconvenience, but we are sincerely concerned about your safety and continued satisfaction with our products. Thank you for giving your attention to this important matter.

 

Sincerely,
Service Support Group
Yamaha Motor Corporation, U.S.A.

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1 Affected Product

Vehicle

MAKE	MODEL	YEAR
YAMAHA	YZFR3	2019

 

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9 Associated Documents

Recall Acknowledgement

RCAK-20V071-4419.pdf 245.138KB

 

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Miscellaneous Document – Factory Modification Campaign

RMISC-20V071-8476.pdf 163.275KB

 

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Defect Notice 573 Report

RCLRPT-20V071-2469.PDF 214.621KB

 

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Recall Quarterly Report #1, 2020-1

RCLQRT-20V071-8716.PDF 211.141KB

 

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Recall Quarterly Report #2, 2020-2

RCLQRT-20V071-4998.PDF 211.237KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V071-7712.pdf 97.323KB

 

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Recall Quarterly Report #3, 2020-3

RCLQRT-20V071-7704.PDF 211.323KB

 

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Recall Quarterly Report #4, 2020-4

RCLQRT-20V071-5102.PDF 211.433KB

 

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Manufacturer Notices(to Dealers,etc) – 2/28/2020 M2020-002R

RCMN-20V071-6027.pdf 1764.625KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V071&docType=RCL

 

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