Brake Caliper Malfunction Due To Corrosion – 2018-2020 Royal Enfield Continental GT 650 & Interceptor 650 Motorcycles

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February 3, 2021 NHTSA CAMPAIGN NUMBER: 21V045000

Brake Caliper Malfunction Due To Corrosion

Corroded brake calipers may cause the brakes to drag or decrease braking performance, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V045

Manufacturer Royal Enfield North America Limited

Components SERVICE BRAKES, HYDRAULIC

 

Summary

Royal Enfield North America Limited (Royal Enfield) is recalling certain 2018-2020 Continental GT 650 and Interceptor 650 motorcycles. Road salt may cause corrosion on the brake calipers.

 

Remedy

Royal Enfield will notify owners, and dealers will replace front and rear calipers, free of charge. Owner notification letters were mailed March 15, 2021. Owners may contact Royal Enfield customer service at 1-414-502-1214.

 

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.

 


Bleeding the Hydraulic Brake System With DOL Tool (Front & Rear)

 

Preparation ( Front Disc Brake)

1. Use a Philips screwdriver to loosen and remove the screws of the front disc brake master cylinder.

2. Remove the cap, and Diaphragm Plate with diaphragm

3. Remove the dust cap and place the suitable ring spanner on the bleeding nipple attach a Vinyl Pipe ( transparent)

4. Thereafter, take a Clean glass / Plastic container (transparent) with fresh brake fluid, and dip the other end of the vinyl pipe (transparent) in it (make sure that the vinyl pipe is always submerged in the fluid during the bleeding process.)

5. Connect the DOL tool switch on the ignition

 

Procedure

1. Select – F1 Diagnosis

2. Select – Royal D1

3. Select – Bosch ABS

4. Default Screen

5. Press C

6. Select – Spl Function

7. Select – Repair Air Bleed

8. Default Screen

9. Default Screen

10. Loosen the bleeder nipple

11. Operate the brake lever

12. Hold the lever in pressed condition and tighten the bleeder nipple

13. Loosen the bleeder nipple – (Brake lever in released condition )

14. * Operate the brake lever till the next window open in DOL

15. Hold the brake lever in pressed condition and tighten the bleeding nipple

* During this operation pump will run and expel the air trapped in the system through bleeder nipple

 

Reassembly

1. Switch off the ignition

2. Disconnect the DOL Tool

3. Remove the vinyl pipe and remove the ring spanner

4. Refit the dust cap ( make sure that there is no leak from the bleeder nipple)

5. Refit the diaphragm with diaphragm plate of the master cylinder

6. Refit the master cylinder cap taking care that the vent slot in the cap is facing rider

 

Preparation ( Rear Disc Brake)

1. Remove the reservoir cap of the rear disc brake

2. Remove the Diaphragm Plate with diaphragm

3. Remove the dust cap and place the suitable ring spanner on the bleeding nipple

4. Attach a Vinyl Pipe ( transparent)

5. Thereafter, take a Clean glass / Plastic container (transparent) with fresh brake fluid, and dip the other end of the vinyl pipe (transparent) in it (make sure that the vinyl pipe is always submerged in the fluid during the bleeding process.)

6.Connect the DOL tool switch on the ignition

 

16. Loosen the bleeder nipple

17. Default Screen

18. Operate the brake lever

19. Hold the brake Pedal in pressed condition and tighten the bleeding nipple

20. Loosen the bleeder nipple – (Brake lever in released condition )

21. * Operate the brake lever till the next window open in DOL

22. Hold the brake lever in pressed condition and tighten the bleeding nipple

* During this operation pump will run and expel the air trapped in the system through bleeder nipple

 

Reassembly

1. Switch off the ignition and disconnect and remove the DOL tool

2. Remove the vinyl pipe and remove the ring spanner

3. Refit the dust cap ( make sure that there is no leak from the bleeder nipple)

4. Refit the diaphragm with diaphragm plate of the reservoir

5. Refit the reservoir cap

 

Bleeding the Hydraulic Brake System Manual (Front & Rear)

Preparation ( Front Disc Brake)

1. Use a Philips screwdriver to loosen and remove the screws of the front disc brake master cylinder.

2. Remove the cap, and Diaphragm Plate with diaphragm

3. Remove the dust cap and place the suitable ring spanner on the bleeding nipple attach a Vinyl Pipe ( transparent)

4. Thereafter, take a Clean glass / Plastic container (transparent) with fresh brake fluid, and dip the other end of the vinyl pipe (transparent) in it (make sure that the vinyl pipe is always submerged in the fluid during the bleeding process.)

 

Bleeding procedure

1. Operate the brake lever to the maximum travel, three to four times and hold the lever in pressed condition

3. Then, use the suitable ring spanner to loosen the bleeding nipple Now you will notice that the brake fluid is coming out of bleeding nipple with air bubbles.

4. As and when brake fluid flow stops tighten the bleeding nipple using suitable ring spanner. Release the brake lever

5. Repeat step (1) through step (5) several times until the discharged fluid is free of air bubbles. And Check the travel of the brake lever. If a firm resistance is felt, the manual bleeding is complete.

6. Do not let the brake master cylinder/reservoir fluid get below the MIN level during the bleeding operation. Keep the master cylinder / reservoir filled with fresh DOT4 brake fluid (never fill the reservoir with the used brake fluid)

 

Reassembly

1. Remove the vinyl pipe and remove the ring spanner

2. Refit the dust cap ( make sure that there is no leak from the bleeder nipple)

3. Refit the diaphragm with diaphragm plate of the master cylinder

4. Refit the master cylinder cap taking care that the vent slot in the cap is facing rider

 

Preparation ( Rear Disc Brake)

1. Remove the reservoir cap of the rear disc brake

2. Remove the Diaphragm Plate with diaphragm

3. Remove the dust cap and place the suitable ring spanner on the bleeding nipple

4. Attach a Vinyl Pipe ( transparent)

5. Thereafter, take a Clean glass / Plastic container (transparent) with fresh brake fluid, and dip the other end of the vinyl pipe (transparent) in it (make sure that the vinyl pipe is always submerged in the fluid during the bleeding process.)

 

Bleeding procedure

1. Operate the brake lever to the maximum travel, three to four times and hold the lever in pressed condition

2. Then, use the suitable ring spanner to loosen the bleeding nipple Now you will notice that the brake fluid is coming out of bleeding nipple with air bubbles.

3. As and when brake fluid flow stops tighten the bleeding nipple using suitable ring spanner. Release the brake lever

4. Repeat step (1) through step (5) several times until the discharged fluid is free of air bubbles. And Check the travel of the brake lever. If a firm resistance is felt, the manual bleeding is complete.

5. Do not let the brake master cylinder/reservoir fluid get below the MIN level during the bleeding operation. Keep the master cylinder / reservoir filled with fresh DOT4 brake fluid (never fill the reservoir with the used brake fluid)

 

Reassembly

1. Remove the vinyl pipe and remove the ring spanner

2. Refit the dust cap { make sure that there is no leak from the bleeder nipple)

3. Refit the diaphragm with diaphragm plate of the reservoir

4. Refit the reservoir cap

 

Bleeding the Hydraulic Brake System Bleeder equipment pneumatic assisted (Front & Rear)

Preparation ( Front Disc Brake)

1. Use a Philips screwdriver to loosen and remove the screws of the front disc brake master cylinder.

2. Remove the cap, and Diaphragm Plate with diaphragm

3. Remove the dust cap and place the suitable ring spanner on the bleeding nipple

4. Make sure that the brake fluid reservoir level is maintained

 

Bleeding procedure

1. Attach the bleeding equipment pipe to the bleeding nipple

2. Attach the other end of the bleeding equipment connecter to the compressed air line

3. Now open the bleeding nipple by using appropriate spanner, and simultaneously press the lever of bleeding equipment for a few seconds and observe that the brake fluid is coming out of the bleeding nipple into the container of the bleeding equipment – if you observe that, air bubble along with brake fluid, continue the above procedure for more duration

4. Simultaneously fill the reservoir to the specified mark and close the bleeding nipple with the help of appropriate spanner

5. And Check the travel of the brake lever. If a firm resistance is felt, the bleeding is complete.

 

Reassembly

1. Disconnect the compressor connection from the equipment and pipe line from the bleeding nipple

2. Refit the dust cap { make sure that there is no leak from the bleeder nipple)

3. Refit the diaphragm with diaphragm plate of the reservoir

4. Refit the reservoir cap

 

Preparation (Rear Disc Brake)

1. Remove the reservoir cap of the rear disc brake

2. Remove the Diaphragm Plate with diaphragm

3. Remove the dust cap and place the suitable ring spanner on the bleeding nipple

4. Make sure that the brake fluid reservoir level is maintained

 

Bleeding procedure

1. Attach the bleeding equipment pipe to the bleeding nipple

2. Attach the other end of the bleeding equipment connecter to the compressed air line

3. Now open the bleeding nipple by using appropriate spanner, and simultaneously press the lever of bleeding equipment for a few seconds and observe that the brake fluid is coming out of the bleeding nipple into the container of the bleeding equipment – if you observe that, air bubble along with brake fluid, continue the above procedure for more duration

4. Simultaneously fill the reservoir to the specified mark and close the bleeding nipple with the help of appropriate spanner

5. And Check the travel of the brake lever. If a firm resistance is felt, the bleeding is complete.

 

Reassembly

1. Disconnect the compressor connection from the equipment and pipe line from the bleeding nipple

2. Refit the dust cap ( make sure that there is no leak from the bleeder nipple)

3. Refit the diaphragm with diaphragm plate of the reservoir

4. Refit the reservoir cap

 

Periodic Maintainence Service & Schedule

1. Use only DOT 4 Brake Fluid

2. Never mix the multi grade brake fluid

3. Every Service inspect the Bundy pipe for damage, leaks, cracks clinks and proper routing.

4. Every Service inspect the Banjo union for its tightness and for leak

5. Maintain the brake fluid level above the minimum level in the reservoir

6. Replace the Brake fluid at every XXXXXXX Km/ XXXXX Months which ever is earlier

7. Replace the Bundy pipe and Banjo bolt at every XXXXX Km/ XXXX Months which ever is earlier (always use new banjo washer)

 


Important Safety Recall Information

Safety Recall Campaign# 21V-045

Dear Royal Enfield Dealers,

Royal Enfield North America (RENA) (A Unit of Eicher Motors Ltd.), has determined to conduct a voluntary safety-related recall in the United States covering models under the names INT 650, Continental GT 650. RENA has discovered a brake caliper corrosion-related issue in a very small number of Interceptor INT 650, Continental GT 650 motorcycles.

RENA has received no reports or complaints from our dealers or customers related to this concern.

Description of the concern outside of North America:

Royal Enfield has discovered a brake caliper corrosion-related issue in a very small number of Interceptor INT 650, Continental GT 650 motorcycles in some specific countries outside of North America. Upon investigation, it was revealed that this corrosion is brought about by sustained, longterm exposure to riding on roads treated with certain salts or a combination of salts, to prevent formation of ice during winters.

This corrosion causes damage to the brake caliper piston bore and assemblies, and can result in unusual braking sound, increased brake drag, unusual difficulty in pushing the motorcycle manually and may impact braking action.

Royal Enfield of North America will begin notifying the affected customers regarding the recall through mail the week of March 22.  The brake calipers both front and rear will be replaced through this process.

 

PLEASE BE ADVISED, IT’S A VIOLATION OF FEDERAL LAW FOR A DEALER TO DELIVER A NEW MOTOR VEHICLE COVERED BY THE NOTIFICATION UNDER A SALE OR LEASE UNTIL THE DEFECT IS REMEDIED

 

Please find attached:

  1. The service circular
  2. Technical reference material
  3. Parts ordering process
  4. Campaign claim / reimbursement process
  5. A copy of the customer letter

 

We ask that you please read these materials thoroughly and share them with all of your staff as soon as possible. Copies of this notification and its attachments can be found on the Google Drive within the dealer Toolbox and can be accessed through this link (Link To Documents)

 

In the meantime, we ask that you and your staff answer any questions your customers may have regarding this subject utilizing the information shared within this dealer communication only. In addition we ask that you contact RENA’s technical service department if you have additional technical questions or concerns regarding this matter, please email us at  RENAService@royalenfield.com or via phone  414-501-3809.

 

DEALER COMMUNICATIONS

February 17th 2021

DC — Campaign SC-14

 

Subject: IMPORTANT DEALER COMMUNICATION!

 

Dear Royal Enfield Dealers:

 

This Service Circular is to inform you about a voluntary Safety recall announcement by Royal Enfield of North America (RENA) pertaining to specific INT 650 and Continental GT 650 models.  It outlines the required replacement of front and rear brake calipers and the appropriate actions to take.

Royal Enfield has discovered a brake caliper corrosion-related issue in a very small number of Interceptor “INT” 650, Continental GT 650 motorcycles in some specific countries outside of North America. Upon investigation, it was revealed that this corrosion is brought about by sustained, long-term exposure to riding on roads treated with certain salts or a combination of salts, to prevent formation of ice during winters. This corrosion causes damage to the brake caliper piston bore and assemblies, and can result in unusual braking sound, increased brake drag, unusual difficulty in pushing the motorcycle manually and may impact braking action.

 

To date, RENA has received no reports or complaints from our dealers or customers related to this concern. RENA has decided to voluntarily launch this recall in the very rare instance this may occur

This recall pertains to model year 2019-2021 INT 650 and Continental GT 650 models.  The brake calipers both front and rear will be replaced through this process.  Please find the Service Circular, Technical instructions, Parts ordering, and claim filing process information on the following pages.

 

Below are the VIN ranges that are potentially affected by this condition:

 

Beginning VIN Ending VIN
ME3FPN476KK ME3FPN471MK
ME3FPN478MK ME3FPN477MK

 

We are including photos as a visual indicator to confirm the completion of this action.  The images below show the visual identification differences between the NONAnodized and Anodized calipers.


SERVICE CIRCULAR Issue no. RE-IB-SC-11-R1
Issue date
Page No 01 of 02
SUBJECT FRONT AND REAR CALIPER ASSEMBLY REPLACEMENT RECALL
APPLICABLE MODELS INT 650, GT 650

 

Attn: Service Manager / Technicians

 

The technical action required to perform this recall are as follows:

The current non-anodized brake calipers (front and rear) will be replaced with anodized calipers (front and rear) The respective service manual outlines the proper procedure for caliper replacement.  For convenience these have been attached.

Please note:

  • The original brake pads should be inspected to ensure they are free of any contaminants and are within their operational specification which is listed in the service manual. Please see Section 9 of the Service Manual – Attached. 
  • If the brake pads are under the minimum specification, contaminated, or functionally compromised, the customer will need to be notified and the brake pads should be replaced. Brake pad replacement will not be covered under this recall. 
  • After the new anodized calipers are installed, the brake system must be bled and the DOL tool must be used to perform the modulator actuation. The process is outlined in Annexure 1 – Attached.

 

Pending approval from NHTSA, the owner letter will include the following direction:

  • IMPORTANT: Should you choose to ride your motorcycle before this safety recall service has been completed, to reduce the risk associated with this condition, we recommend that you evaluate your motorcycle BEFORE each ride per the following procedure: o With your bike in neutral – o Fully depress rear brake pedal and release. o Fully squeeze front brake lever and release.
    • Slightly rock the motorcycle back and forth to ensure that brakes have released normally and increased brake drag is not present.
    • NOTE: If increased brake drag from either the front or rear brake is noted, your motorcycle may be exhibiting the recall condition.

 

Part Details and Ordering Process

Due to low part availability dealer orders containing caliper part numbers will not be fulfilled. We will provide an initial wave shipment of anodized replacement calipers and will be shipped to your dealership starting the week of February 22nd 2021. A dealer communication will be released to notify that sufficient stock is available and dealer ordering may begin. Calipers will be invoiced per transaction and will be filed for reimbursement with labor in the warranty claim submission process.

Part Description New Part Number
FRONT CALIPER KAB00267/A
REAR CALIPER KAB00268/A

 

Claim filing 

RENA will reimburse parts and labor cost under the standard warranty process using job type “Campaign” and Campaign type “Campaign SC 14”. This reimbursement will also cover consumables and administrative time:  See the attached screenshots as an aid.

 

Upon completion of caliper (front and rear) replacement, use the standard claim submission process within the DMS.  Listed below are filing details specific to this campaign.  Please use the following part numbers and warranty flat rate time (frt) to complete the claim:(INSERT IMAGE)

 

Job type:  Campaign

Campaign Type: Campaign SC 14

 

Part numbers:

Front Caliper –  KAB00267/A

Rear Caliper –  KAB00268/A

 

Labor Codes:

Front Caliper –  INGT-WBFB001  .4 hours

Rear Caliper –  INGT-WBRB001  .4 hours

 

If you have any questions, please contact Technical service at

Renaservice@royalenfield.com or call 414-501-3809

 

Sincerely,

Royal Enfield of North America

 


6 Affected Products

Vehicles

MAKE MODEL YEAR
ROYAL ENFIELD CONTINENTAL GT 650 2018-2020
ROYAL ENFIELD INTERCEPTOR 650 2018-2020

 


12 Associated Documents

Remedy Instructions and TSB

RCRIT-21V045-8952.pdf 642.029KB

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Recall Acknowledgement

RCAK-21V045-9673.pdf 689.777KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V045-8716.pdf 87.534KB

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Recall 573 Report-Amendment 1

RCLRPT-21V045-5820.PDF 218.777KB

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Recall Quarterly Report #1, 2021-1

RCLQRT-21V045-2992.PDF 211.144KB

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Recall 573 Report-Amendment 2

RCLRPT-21V045-9867.PDF 219.288KB

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Manufacturer Notices(to Dealers,etc) – February 16th 2021 Subject: IMPORTANT DEALER COMMUNICATION! Voluntary Safety Recall Campaign SC-14

RCMN-21V045-2126.pdf 414.489KB

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Manufacturer Notices(to Dealers,etc) – Service manual section 9

RCMN-21V045-2123.pdf 4919.395KB

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Manufacturer Notices(to Dealers,etc) – Annexure 1 Bleeding the Hydraulic Brake System With DOL Tool (Front & Rear)

RCMN-21V045-9983.pdf 6404.457KB

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Recall Quarterly Report #3, 2021-3

RCLQRT-21V045-0418.PDF 211.324KB

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Recall Quarterly Report #2, 2021-2

RCLQRT-21V045-0720.PDF 211.244KB

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Recall Quarterly Report #4, 2021-4

RCLQRT-21V045-8658.PDF 211.437KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V045&docType=RCL

 


 

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