990139 – Decreased Reflectiveness of Rear Reflector Lens – 2015-2020 Yamaha YZF-R3, 2020 MT03 & 2018-2020 XMAX Scooters

October 5, 2020 NHTSA CAMPAIGN NUMBER: 20V611000

Decreased Reflectiveness of Rear Reflector Lens

A less reflective rear reflector increases the risk of crash.

 

NHTSA Campaign Number: 20V611

Manufacturer Yamaha Motor Corporation, USA

Components VISIBILITY

Potential Number of Units Affected 31,000

 

Summary

Yamaha Motor Corporation, USA (Yamaha) is recalling certain 2015-2020 YZF-R3, 2020 MT03 and 2018-2020 XMAX scooters. Condensation or other contaminates may adhere to the rear reflector lens reducing its effectiveness.

 

Remedy

Yamaha will notify owners, and dealers will replace the rear reflector, free of charge. The recall began October 20, 2020. Owners may contact Yamaha customer service at 1-888-266-3085. Yamaha’s number for this recall is 990139.

 

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

 

---

10/20/2020

M2020-007R

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.

 

2015~2020-MODEL YZF-R3 AND 2020-MODEL MT-03 MOTORCYCLES, AND 2018~2020-MODEL XMAX SCOOTERS

FACTORY MODIFICATION CAMPAIGN – Rear Reflector Assembly

 

INTRODUCTION

Yamaha Motor Corporation, U.S.A. has decided that a defect that relates to motor vehicle safety exists in 2015~2020-model YZF-R3 and 2020-model MT-03 motorcycles, and 2018~2020-model XMAX (CZD300) scooters.

In affected motorcycles and scooters, the rear reflector assembly may not comply with motor vehicle safety standards related to reflection luminosity. This is due to condensation or other contaminants adhering to the lens mold that compromised the reflective properties of the lens, increasing the risk of a crash.

To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the rear reflector assembly replaced with the proper parts that address the reflection issue.

Yamaha is notifying all registered owners of affected motorcycles and scooters by mail. A copy of this letter is included in this bulletin. The customer should take this letter along with the affected scooter or 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 and scooters invoiced to your dealership is included with a mailed copy of this bulletin. Use the list to help ensure all motorcycles and scooters are modified. All sold motorcycles and scooters that have been registered with Yamaha will show the customer’s name and address.

Your dealership must notify the owner of any affected motorcycle or scooter that was actually sold but listed as “unsold” in the report. You must modify all affected motorcycles and scooters in your inventory as well as all customer-owned motorcycles and scooters brought to you for this service. Any affected motorcycle or scooter that you purchase from Yamaha in the future may also require modification. If you purchase a motorcycle or scooter from another dealer or Yamaha, check to see if the procedures in this bulletin have already been performed before you sell the motorcycle or scooter.

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

When the modification on each motorcycle or scooter 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:	Use Unit Status on YDS to check to be sure the unit is affected and that it has not already been modified.
Parts Required:	Yes. Order a new rear reflector assembly kit for each affected unit. See the Parts Information section of this bulletin for more information.
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 whose motorcycle or scooter shows as unregistered on the enclosed report. Yamaha has sent letters to customers whose motorcycles and scooters were registered with Yamaha as of 10/19/2020.

 

AFFECTED RANGE

Check Unit Status on YDS to make sure the Primary ID (PID) is in the Affected Range and is eligible for this repair. The affected unit ranges for this issue are:

Year	Model	Model Code	Primary ID
			Prefix	From	To
2015 ~ 2018	YZF-R3	2MS1, 2MS3, 2MS5, 2MS7	RH06Y	0001001	0018560
2017 ~ 2018	YZF-R3A	BY91, BY93	RH15Y	0001001	0004360
2019 ~ 2020	YZF-R3	B8P1, B8P3	RH17Y	0001001	0003560
2019 ~ 2020	YZF-R3A	B5L2, B5LC, B5LE	RH18Y	0001001	0004920
2020	MT-03	B5W2	RH20Y	0001001	0003240
2018 ~ 2020	XMAX (CZD300)	B747, B74F, B74J	SH10Y	0001001	0002636

 

IMPORTANT: Affected Primary IDs may not be consecutive. Always check YDS Unit Status before starting any repair.

 

SERVICE PROCEDURES

REPLACE REAR REFLECTOR (YZF-R3, MT-03)

To replace the rear reflector assembly, follow the procedures outlined below:

1. To prevent damage, cover any painted parts near the mud guard.

2. Remove the mud guard assembly by removing the following hardware:

 

2015~2018 YZF-R3

34 – Bolt 10mm (4pc)
33 – Rear Fender Cover
24 – Bolt (2pc), Torque: 3.8Nm (0.38 kgf-m, 2.8 lb-ft)
24 – Bolt (2pc), Torque: 3.8Nm (0.38 kgf-m, 2.8 lb-ft)
25 – Bolt (4pc), Torque 2.5Nm (0.25 kgf-m, 1.8 lb-ft)
22 – Bolt (2pc), Torque 6.5Nm (0.65 kgf-m, 4.8 lb-ft)
29 – Damper (2pc)
21 – Fender Bracket

 

2019~2020 YZF-R3 and 2020 MT-03

36 – Bolt 10mm (4pc)
23 – Rear Fender Cover
26 – Bolt (2pc), Torque: 3.8Nm (0.38 kgf-m, 2.8 lb-ft)
26 – Bolt (2pc), Torque: 3.8Nm (0.38 kgf-m, 2.8 lb-ft)
27 – Bolt (4pc), Torque 2.5Nm (0.25 kgf-m, 1.8 lb-ft)
24 – Bolt (2pc), Torque 6.5Nm (0.65 kgf-m, 4.8 lb-ft)
31 – Damper (2pc)
23 – Fender Bracket

 

3. Remove the nut and washer that secures the rear reflector by using a 10mm socket.

4. Remove the rear reflector and replace it with the new reflector assembly kit. The nut and washer will be reused.

5. Install the new rear reflector.

• Match the locating pin on the reflector with the locating hole on the mud guard assembly.

• Install the original washer and nut on the rear reflector assembly .

• Tighten the rear reflector mounting nut to the    specified torque: 1.5Nm (0.15 kgf-m, 1.1 lb-ft).

• Reinstall the mud guard assembly in the reverse Tighten all mounting hardware to the torque specified in step 2.

6. Discard the old reflector to prevent it from being accidentally reused.

 

REPLACE REAR REFLECTOR (XMAX)

1. Position the scooter upright using its main stand. Cover any painted parts near the rear of the scooter to avoid damage.

2. Remove the box (trunk) assembly:

• Disconnect the baggage lamp and remove the five retaining bolts . The bolts will be reused.

• Spread the lower side cover (left side shown) slightly outward. Release the box lip and remove the box assembly.

3. Remove the mounting bolts for the rear side cover  and then remove the rear side cover.

4. Remove the rear reflector nut and remove the rear reflector .

5. Install the replacement reflector assembly kit.

• Match the locating pin on the rear reflector assembly with the mating hole on the cowling assembly.

• Install the original washer and nut and tighten to 1.5Nm (0.15 kgf-m, 1.1 lb-ft).

• Reinstall the rear side cover and box in reverse Tighten all bolts and nuts to 1.8Nm (0.18 kgf-m, 1.3 lb-ft.

6. Discard the old reflector to prevent it from being accidentally reused.

 

IDENTIFICATION PROCEDURE

After completing the procedure, make sure to properly record and submit the warranty claim for this campaign to ensure correct reimbursement and to update the unit’s repair history in Yamaha’s database.

 

PARTS INFORMATION

Order the rear reflector assembly kit.

PART NUMBER	DESCRIPTION	QTY	APPLICATION	DEALER COST
90891-30140-00	Rear Reflector Assembly	1	YZF-R3, MT-03,  XMAX (CZD300)	$0.06 ea.

 

WARRANTY INFORMATION

The owner of each registered motorcycle or scooter will receive a letter announcing this campaign. The customer’s letter includes the Vehicle Identification Number (VIN) and Recall Number.

The modification is authorized for all affected motorcycles and scooters, 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 as described below using Campaign Number 990139. The labor allowance is 0.2 hours.

 

YDS:

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

 

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).

 

---

IMPORTANT SAFETY RECALL NOTICE

This notice applies to your motorcycle or scooter, VIN xxxxxxxxxxxxxxxxx   Model:

 

October 20, 2020
990139

 

Dear Yamaha Owner:

Yamaha Motor Corporation, U.S.A. has decided that a defect that relates to motor vehicle safety exists in 2015~2020-model YZF-R3 and 2020-model MT-03 motorcycles, and 2018~2020-Model XMAX (CZD300) scooters. Our records indicate you own the affected vehicle show above.

 

The reason for this recall:

In affected motorcycles and scooters, the rear reflector assembly may not comply with motor vehicle safety     standards related to reflection luminosity. This is due to condensation or other contaminants adhering to the lens mold that compromised the reflective properties of the lens, increasing the risk of a crash

 

What Yamaha and your dealer will do:

Your authorized Yamaha dealer will replace your motorcycle’s or scooter’s rear reflector with one that was properly manufactured. The procedure takes a little less than 15 minutes to perform, but your dealer may need to keep your motorcycle or scooter longer. 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 this procedure performed. At that same time, you can find out how long they expect to keep your motorcycle or scooter for this service. Remember to take this letter with you when you take in your motorcycle or scooter.

If you are unable to return to the Yamaha dealer who sold you the motorcycle or scooter, this service will be performed by any authorized Yamaha Motorcycle or Scooter dealer. For the name of a dealer near you, call 1-800-88-YAMAHA or visit the Yamaha web site 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 1-888-327-4236 (TTY: 1-800- 424-9153); or go to https://www.safercar.gov. Refer to NHTSA recall number 20V611.

 

If you no longer own this Yamaha:

If you have sold your motorcycle or scooter 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 Vehicle Identification Number (VIN) shown above your name on this letter.

 

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,

 

Motorsports Service Support

Yamaha Motor Corporation, U.S.A.

 

---

10 Affected Products

Vehicles

MAKE	MODEL	YEAR
YAMAHA	MT-03	2020
YAMAHA	XMAX	2018-2020
YAMAHA	YZF-R3	2015-2020

 

---

9 Associated Documents

Recall Quarterly Report #1, 2020-4

RCLQRT-20V611-5417.PDF 211.148KB

 

---

Recall Quarterly Report #2, 2021-1

RCLQRT-20V611-0784.PDF 211.249KB

 

---

Recall Acknowledgement

RCAK-20V611-5536.pdf 244.127KB

 

---

Defect Notice 573 Report

RCLRPT-20V611-8013.PDF 216.428KB

 

---

Recall Quarterly Report #3, 2021-2

RCLQRT-20V611-8466.PDF 211.336KB

 

---

Recall 573 Report-Amendment 1

RCLRPT-20V611-9391.PDF 216.499KB

 

---

Manufacturer Notices(to Dealers,etc) – 10/20/2020 M2020-007R

RCMN-20V611-9081.pdf 2088.111KB

 

---

ISSUED Owner Notification Letter(Part 577)

RCONL-20V611-9561.pdf 206.078KB

 

---

Recall Quarterly Report #4, 2021-3

RCLQRT-20V611-1529.PDF 211.439KB

 

---

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=20V611&docType=RCL

 

---