Improper Installation of Index Spring – 2021-2022 Buell 1190 RX & SX Motorcycles

Defect Notice 573 Report

RCLRPT-23V257-4525.PDF 214.43KB

Recall Acknowledgement

RCAK-23V257-7297.pdf 693.854KB

Remedy Instructions and TSB

RCRIT-23V257-9671.pdf 1181.677KB

SEOCONTENT-START

INFORMATION REDACTED PURSUANTTOTHE FREEDOM
OF INFORMATION ACT {FOIA), 5 U.S.C.552{8){6)
Buell.
Buell Motorcycle Co.
2700 Patterson Ave SE, Grand Rapids, Ml 49546
www.BuellMotorcycle.com I info@buellmotorcycle.com
SAFE TY This modification has top priority. This bulletin must be performed
immediately to ensure customer safety. RE CA L L NOTE Bulletins that announce a recall will have an “R” at the end of the bulletin number
CERTAIN 2021 ~ 2022 1190 RX and SX MODELS
FACTORY MODIFICATION CAMPAIGN – Incorrect Index Spring Placement
i I •NTKODUCTION
Buell Motorcycle Company (“Buell”). has decided that a defect
which relates to motor vehicle safety exists in certain 2021 ~ 2022
1190 RX and SX motorcycles. In affected motorcycles, the index
spring for the gear shift shaft may be improperly installed. If the
index spring is improperly installed, it could be difficult to shift
gears, which could result in loss of control and a crash with injury
or death.
To correct this defect, Buell is initiating a NHTSA Recall
Campaign. Affected units must have the index spring position
corrected with a new bolt and other kit contents.
Buell is notifying all registered owners of affected motorcycles by
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 Buell Service Center for modification.
If you were invoiced for one or more affected units, a computerized report listing all affected motorcycles invoiced
to you is mailed with this bulletin. Use the list to help ensure all affected motorcycles are modified. All sold
motorcycles that have been registered with Buell 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 Buell, 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 Buell
policy for you 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.
l.b~ I DfALER. ACTION SUMMARY
Unsold &
Sold Units: Contact Buell at info@buellmotorcycle.com to check to be sure the unit is affected and that it is not
already modified, and then properly install the Index Spring Kit as instructed in this bulletin.
Parts: Yes. A Recall Service Parts Kit, NHTSA 23V257, will be sent for each affected unit. 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 Yes, you must immediately contact any customer if a motorcycle shows as unregistered on the
Customers: enclosed report. Buell has sent letters to customers whose motorcycles were registered with
Buell as of April 25, 2023.
Important:
1~~1 AFFECTED RANGE
Model
From
VIN Range
2021 Buell 1190 SX 546BBAG21 ML
2021 Buell 1190 Hammerhead RX 546AAAG23ML
2022 Buell 1190 SX 546BBAG2XNL
2022 Buell 1190 Hammerhead RX 546AAAG21 NL
I ~ I SER.VICE PROCEDURES
Refer to the Index Spring Orientation Instruction to reinstall the index spring found
https://buellmotorcycle.com/support.
Each kit will also include the Index Spring Orientation Instruction for this recall.
To
546BBAG25M
546AAAG27M
546BBAG2XN
546AAAG23NL
I ~ti IDENTIFICATION PROCEDURE
After 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 Buell’s database.
The correct placement can be identified by:
Part Name Incorrect Orientation Correct Orientation
Spring, Index (CG0003.1 B7)
Behind Boss In Front of Boss
Assembly Incorrect Order of Assembly Correct Order of Assembly
CAUTION: Please ensure the
washer is assembled behind the
shift lever as pictured
Washer between Lever and Bolt Washer behind Lever
l–Ji,
~ @:.~ PARTS INFORMATION
Order a kit using the Buell Recall Parts Order Form found at https://buellmotorcycle.com/support for each
affected unit.
Part Number Kit Part Name Dealer Cost
C1260.23A0 RECALL SERVICE PARTS KIT, NHTSA 23V257 $ 133.07
KIT CONTENTS:
0
0
No. P-art Name Part Number Quantity
1 HEADER FLANGE GASKET S0181.187 1
2 EXHAUST GASKET INLET FRONT S0185.187 1
3 EXHAUST GASKET INLET REAR S0186.187 1
4 EAR CLAMP, 31.4-34.6MM CN0025.1AY 1
5 O-RING, OIL FILTER CF0003.186 1
6 FILTER, OIL Q0064.1B6 1
7 SEALING RING, OIL DRAIN PLUG1, M12 Q0091 .186 1
8 SEALING RING, OIL DRAIN PLUG2, M18 Q0092.186 1
9 RING, SEALING, 6X10 CJ0001 .1B6 2
10 GASKET, WATER PUMP Q0426.186 1
11 CLAMP, 9.6-1 1.3 MM CN0047.187 1
12 GASKET, DIAPHRAGM COVER R0009.1 B6 1
13 GASKET, CLUTCH COVER R0001.186 1
14 BOLT, M6X16 CA0059.186 1
15 ZIP TIES Y0303.1B6 10
16 AMSOIL (1 GALLON) Q0750A.187 1
The owner of each registered unit will receive a letter announcing this campaign. The customer’s letter includes
the Vehicle Identification Number and Recall Number.
The modification is authorized for all affected vehicles, 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.
To submit a Recall Claim for the parts and labor visit https://buellmotorcycle.com/support, complete the required
documents and submit it along with the visual aid to verify the proper installation has been completed. The labor
allowance for this recall is 6 hours.
Ensure a visual aid is captured of the proper installation of the index spring, washer, shift lever, and bolt
(step 56 in Index Spring Orientation Instruction Process) and submit to service@buellmotorcycle.com.
Claim may be denied by Buell if identifiable photo is not captured and submitted.
jl~ J1 . ~ WARRANTY INFORMATION

**************************************************************************************************************

Buell Motorcycle Co.
2700 Patterson Ave SE, Grand Rapids, MI 49546
www.BuellMotorcycle.com | info@buellmotorcycle.com
Jane Doe
4567 Main ST
Anytown PA 98765-3210
IMPORTANT SAFETY RECALL
This notice applies to your vehicle, VIN # [VIN].
Buell Recall No. 0001
NHTSA Recall No. 23V257
[Date]
Dear [Owner],
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Buell Motorcycle Company (“Buell”) has determined that a defect, which relates to motor
vehicle safety, exists in certain 2021-2022 Buell 1190 Hammerhead RX and SX motorcycles.
WHY DOES MY VEHICLE NEED REPAIRS?
The index spring (CG0003.1B7) which applies a locking force to the gear select shift drum may
be anchored in an incorrect position. If that condition exists, the rider may experience one or
more of the following conditions: a) driver actuated shifts between gears may feel more vague
(not as precise), b) the motorcycle may upshift or downshift a gear without rider input, or c) the
motorcycle may “hang” between gears creating a false neutral or in rare cases, cause the
transmission to lock up. Any of these conditions could cause temporary loss of control of the
motorcycle, increasing the risk of a crash without prior warning. Malfunction may occur at any
time while operating the motorcycle.
WHAT WILL BUELL AND YOUR AUTHORIZED SERVICE CENTER DO?
Buell has arranged for its Authorized Service Centers to inspect and ensure proper installation of
the index spring, free of charge. The earliest date service facilities will receive necessary parts
and instructions will be May 8th, 2023.
The repair should take approximately 6 hours to complete. However, due to scheduling, your
authorized service center may require your motorcycle for longer. Your authorized service
center should be able to provide a more accurate repair time estimate. Remember to take this
letter with you when you take in your motorcycle. There will be no charge to you for this repair
procedure.
WHAT SHOULD YOU DO?
Please contact your local authorized service center and schedule an appointment for your free
repair as soon as possible. The accompanying insert to this letter provides the location, phone
number, and other important contact information on your recommended authorized service
center location.
Only ride your motorcycle to the Authorized Service Center to be repaired. You should
avoid riding your affected motorcycle shown above whenever possible until you can take it
to the Authorized Service Center to have the recall repair performed.
WHO SHOULD YOU CONTACT WITH FURTHER QUESTIONS OR CONCERNS?
If, after your Authorized Service Center, you have questions or concerns, please contact Buell at
2700 Patterson Ave SE
Grand Rapids, MI 49546
info@buellmotorcycle.com
(262) 624-1627
You may submit a complaint to the National Highway Traffic Safety Administration, 1200 New
Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at
1–888–327–4236 (TTY: 1–800–424–9153); or go to http://www.safercar.gov, if you believe
that:
(A) Buell or the Authorized Service Center has failed or is unable to remedy the defect
without charge.
(B) The manufacturer has failed or is unable to remedy the defect without charge within a
reasonable time, which is not longer than 60 days after you first deliver the vehicle to an
Authorized Service Center following the earliest repair date specified in this notification.
WHAT IF YOU ARE A LESSOR?
Federal law requires that you forward a copy of this safety recall notice to the lessee within 10 days
of receiving this notice.
WHAT IF YOU HAVE ALREADY PAID FOR THIS REPAIR?
You may be eligible to receive reimbursement for the cost of repairs made prior to receiving this
notice. You may submit your receipts along with the Reimbursement Request Form found
online at https://www.buellmotorcycle.com/reimbursement by mail to 2700 Patterson Ave SE,
Grand Rapids MI, 49546.
WHAT IF YOU NO LONGER OWN THE VEHICLE?
If you no longer own the vehicle, please call us at (262) 624-1627 with the name and
address of the new owner, along with the VIN number shown above your name on the
address label above.
We apologize for any inconvenience and thank you for your attention to this safety matter.
Sincerely,
[Manufacturer/Campaign Administrator]

**************************************************************************************************************

Buell Motorcycle Co.
2700 Patterson Ave SE, Grand Rapids, MI 49546
www.BuellMotorcycle.com | info@buellmotorcycle.com
Owner Name
Owner Address
IMPORTANT SAFETY RECALL
This notice applies to your vehicle, VIN #
Buell Recall No. 0001
NHTSA Recall No. 23V257
May 5, 2023
Dear Name,
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Buell Motorcycle Company (“Buell”) has determined that a defect, which relates to motor
vehicle safety, exists in certain 2021-2022 Buell 1190 Hammerhead RX and SX motorcycles.
WHY DOES MY VEHICLE NEED REPAIRS?
The index spring (CG0003.1B7) which applies a locking force to the gear select shift drum may
be anchored in an incorrect position. If that condition exists, the rider may experience one or
more of the following conditions: a) driver actuated shifts between gears may feel more vague
(not as precise), b) the motorcycle may upshift or downshift a gear without rider input, or c) the
motorcycle may “hang” between gears creating a false neutral or in rare cases, cause the
transmission to lock up. Any of these conditions could cause temporary loss of control of the
motorcycle, increasing the risk of a crash without prior warning. Malfunction may occur at any
time while operating the motorcycle.
WHAT WILL BUELL AND YOUR AUTHORIZED SERVICE CENTER DO?
Buell has arranged for its Authorized Service Centers to inspect and ensure proper installation of
the index spring, free of charge. The earliest date service facilities will receive necessary parts
and instructions will be May 8th, 2023.
The repair should take approximately 6 hours to complete. However, due to scheduling, your
authorized service center may require your motorcycle for longer. Your authorized service
center should be able to provide a more accurate repair time estimate. Remember to take this
letter with you when you take in your motorcycle. There will be no charge to you for this repair
procedure.
WHAT SHOULD YOU DO?
Please contact your local authorized service center and schedule an appointment for your free
repair as soon as possible. The accompanying insert to this letter provides the location, phone
number, and other important contact information on your recommended authorized service
center location.
Only ride your motorcycle to the Authorized Service Center to be repaired. You should
avoid riding your affected motorcycle shown above whenever possible until you can take it
to the Authorized Service Center to have the recall repair performed.
WHO SHOULD YOU CONTACT WITH FURTHER QUESTIONS OR CONCERNS?
If, after your Authorized Service Center, you have questions or concerns, please contact Buell at
2700 Patterson Ave SE
Grand Rapids, MI 49546
info@buellmotorcycle.com
(262) 624-1627
You may submit a complaint to the National Highway Traffic Safety Administration, 1200 New
Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at
1–888–327–4236 (TTY: 1–800–424–9153); or go to http://www.safercar.gov, if you believe
that:
(A) Buell or the Authorized Service Center has failed or is unable to remedy the defect
without charge.
(B) The manufacturer has failed or is unable to remedy the defect without charge within a
reasonable time, which is not longer than 60 days after you first deliver the vehicle to an
Authorized Service Center following the earliest repair date specified in this notification.
WHAT IF YOU ARE A LESSOR?
Federal law requires that you forward a copy of this safety recall notice to the lessee within 10 days
of receiving this notice.
WHAT IF YOU HAVE ALREADY PAID FOR THIS REPAIR?
You may be eligible to receive reimbursement for the cost of repairs made prior to receiving this
notice. You may submit your receipts along with the Reimbursement Request Form found
online at https://www.buellmotorcycle.com/reimbursement by mail to 2700 Patterson Ave SE,
Grand Rapids MI, 49546.
WHAT IF YOU NO LONGER OWN THE VEHICLE?
If you no longer own the vehicle, please call us at (262) 624-1627 with the name and
address of the new owner, along with the VIN number shown above your name on the
address label above.
We apologize for any inconvenience and thank you for your attention to this safety matter.
Sincerely,

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-257
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Buell Motorcycles AUG 16, 2023 NHTSA Recall No. : 23V-257 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Buell Motorcycles Address : 2700 Patterson Ave SE
Grand Rapids MI 49546
Company phone : 6167195917
Population :
Number of potentially involved : 30 Estimated percentage with defect : 90 %
Vehicle Information : Vehicle 1 : 2021-2022 Buell Motorcycles 1190 RX and SX Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : Recall population was determined by how many motorcycles were assembled with outdated process sheets. The products not included in the recall have been assembled using the correct process, with 2 step verification on the production line. This issue has affected 50 motorcycles, and they can be found within the United States.
Production Dates : NOV 01, 2021 – DEC 31, 2022
VIN Range 1 : Begin : 546AAAG23ML000001 End : 546AAAG27ML000003 Not sequential VIN Range 2 : Begin : 546AAAG21NL000001 End : 546AAAG26NL000012 Not sequential VIN Range 3 : Begin : 546BBAG21ML000001 End : 546BBAG25ML000003 Not sequential VIN Range 4 : Begin : 546BBAG2XNL000001 End : 546BBAG26NL000013 Not sequential Description of Defect :
Description of the Defect : Possible incorrect installation of index spring. The spring should be laying against the boss in the case, however, some may be resting against the side of the engine case. This shift in positioning reduces the spring force being applied.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Bike may not shift into rider intended gear. Could potentially slip out of gear without warning.Any of these conditions could cause temporary loss of control of the
motorcycle, increasing the risk of a crash without prior warning. Malfunction may occur at any
time while operating the motorcycle. Description of the Cause : The cause of this issue was due to an incorrect process of assembly. The Part 573 Safety Recall Report 23V-257 Page 2 Identification of Any Warning
that can Occur : process sheet did not specify the orientation of this spring causing the line to install them incorrectly.
Gear shifts may appear to feel sloppy, and inconsistent. Neutralizing between gears. Up or down shift without input. Involved Components : Component Name 1 : Index Spring
Component Description : Spring that applies force to the index shim Component Part Number : CG0003.1B7 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
On March 12th, 2023, preliminary riding of a factory bike was completed out of state, abnormal shifting, shifting without input, and neutralizing was detected. On March 28th, 2023, the quality team went to investigate the assembly process. On March 28th, 2023, upon evaluating the process, an installation error was found that the index spring was installed in the incorrect position. On March 29th, 2023, the factory bike in question was disassembled and further investigated, providing confirmation of the incorrect index spring positioning. On April 3, 2023, the decision was made to conduct a recall to remedy this issue. Description of Remedy :
Description of Remedy Program : All motorcycles that have been manufactured by Buell Motorcycles, public
and internally, will have spring installed in the correct position. Some recall services will be completed at the Buell Factory, and some at certified service centers. The process of disassembly, index spring correction, and reassembly as well as the parts required will be provided to the service centers by Buell. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-257
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production :
The remedy component (spring) is the same as the recalled component – the remedy is to install the spring in the correct orientation. The index spring should be rotated clockwise and sit in the indented location. The difference will be an increased spring force applied to the index shim, allowing the bike to stay in gear and shift accordingly.
The recall has been corrected in production April 3rd by updating the process sheet and providing visual aids to ensure proper installation going forward. Training will be completed to ensure proper placement. Recall Schedule :
Description of Recall Schedule : The initial letter to the owners as well as the dealers will be sent out
within the required 60-day time frame. The initial letters will be released to the dealers and owners on April 14 detailing the recall. There will be a subsequent letter to the owners to schedule their service followed by the process and required parts will then be sent to the service centers. .
Planned Dealer Notification Date : APR 14, 2023 – APR 28, 2023
Planned Owner Notification Date : APR 14, 2023 – APR 28, 2023
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-257
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Buell Motorcycles AUG 16, 2023 NHTSA Recall No. : 23V-257 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Buell Motorcycles Address : 2700 Patterson Ave SE
Grand Rapids MI 49546
Company phone : 6167195917
Population :
Number of potentially involved : 30 Estimated percentage with defect : 90 %
Vehicle Information : Vehicle 1 : 2021-2022 Buell Motorcycles 1190 RX and SX Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : Recall population was determined by how many motorcycles were assembled with outdated process sheets. The products not included in the recall have been assembled using the correct process, with 2 step verification on the production line. This issue has affected 50 motorcycles, and they can be found within the United States.
Production Dates : NOV 01, 2021 – DEC 31, 2022
VIN Range 1 : Begin : 546AAAG23ML000001 End : 546AAAG27ML000003 Not sequential VIN Range 2 : Begin : 546AAAG21NL000001 End : 546AAAG26NL000012 Not sequential VIN Range 3 : Begin : 546BBAG21ML000001 End : 546BBAG25ML000003 Not sequential VIN Range 4 : Begin : 546BBAG2XNL000001 End : 546BBAG26NL000013 Not sequential Description of Defect :
Description of the Defect : Possible incorrect installation of index spring. The spring should be laying against the boss in the case, however, some may be resting against the side of the engine case. This shift in positioning reduces the spring force being applied.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Bike may not shift into rider intended gear. Could potentially slip out of gear without warning.Any of these conditions could cause temporary loss of control of the
motorcycle, increasing the risk of a crash without prior warning. Malfunction may occur at any
time while operating the motorcycle. Description of the Cause : The cause of this issue was due to an incorrect process of assembly. The Part 573 Safety Recall Report 23V-257 Page 2 Identification of Any Warning
that can Occur : process sheet did not specify the orientation of this spring causing the line to install them incorrectly.
Gear shifts may appear to feel sloppy, and inconsistent. Neutralizing between gears. Up or down shift without input. Involved Components : Component Name 1 : Index Spring
Component Description : Spring that applies force to the index shim Component Part Number : CG0003.1B7 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
On March 12th, 2023, preliminary riding of a factory bike was completed out of state, abnormal shifting, shifting without input, and neutralizing was detected. On March 28th, 2023, the quality team went to investigate the assembly process. On March 28th, 2023, upon evaluating the process, an installation error was found that the index spring was installed in the incorrect position. On March 29th, 2023, the factory bike in question was disassembled and further investigated, providing confirmation of the incorrect index spring positioning. On April 3, 2023, the decision was made to conduct a recall to remedy this issue. Description of Remedy :
Description of Remedy Program : All motorcycles that have been manufactured by Buell Motorcycles, public
and internally, will have spring installed in the correct position. Some recall services will be completed at the Buell Factory, and some at certified service centers. The process of disassembly, index spring correction, and reassembly as well as the parts required will be provided to the service centers by Buell. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-257
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production :
The remedy component (spring) is the same as the recalled component – the remedy is to install the spring in the correct orientation. The index spring should be rotated clockwise and sit in the indented location. The difference will be an increased spring force applied to the index shim, allowing the bike to stay in gear and shift accordingly.
The recall has been corrected in production April 3rd by updating the process sheet and providing visual aids to ensure proper installation going forward. Training will be completed to ensure proper placement. Recall Schedule :
Description of Recall Schedule : The initial letter to the owners as well as the dealers will be sent out
within the required 60-day time frame. The initial letters will be released to the dealers and owners on April 14 detailing the recall. There will be a subsequent letter to the owners to schedule their service followed by the process and required parts will then be sent to the service centers. .
Planned Dealer Notification Date : APR 14, 2023 – APR 28, 2023
Planned Owner Notification Date : APR 14, 2023 – APR 28, 2023
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-257
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Buell Motorcycles APR 07, 2023 NHTSA Recall No. : 23V-257 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Buell Motorcycles Address : 2700 Patterson ave SE
Grand Rapids MI 49546
Company phone : 6167195917
Population :
Number of potentially involved : 30 Estimated percentage with defect : 90 %
Vehicle Information : Vehicle 1 : 2021-2022 Buell Motorcycles 1190 RX and SX Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : Recall population was determined by how many motorcycles were assembled with outdated process sheets. The products not included in the recall have been assembled using the correct process, with 2 step verification on the production line. This issue has affected 50 motorcycles, and they can be found within the United States.
Production Dates : NOV 01, 2021 – DEC 31, 2022
VIN Range 1 : Begin : 546AAAG23ML000001 End : 546AAAG27ML000003 Not sequential VIN Range 2 : Begin : 546AAAG21NL000001 End : 546AAAG26NL000012 Not sequential VIN Range 3 : Begin : 546BBAG21ML000001 End : 546BBAG25ML000003 Not sequential VIN Range 4 : Begin : 546BBAG2XNL000001 End : 546BBAG26NL000013 Not sequential Description of Defect :
Description of the Defect : Possible incorrect installation of index spring. The spring should be laying against the boss in the case, however, some may be resting against the side of the engine case. This shift in positioning reduces the spring force being applied.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Bike may not shift into rider intended gear. Could potentially slip out of gear without warning.
Description of the Cause : The cause of this issue was due to an incorrect process of assembly. The process sheet did not specify the orientation of this spring causing the line to install them incorrectly. Identification of Any Warning
that can Occur : Gear shifts may appear to feel sloppy, and inconsistent. Neutralizing between
thout input. Part 573 Safety Recall Report 23V-257 Page 2 Involved Components : Component Name 1 : Index Spring
Component Description : Spring that applies force to the index shim Component Part Number : CG0003.1B7 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
On March 12th, 2023, preliminary riding of a factory bike was completed out of state, abnormal shifting, shifting without input, and neutralizing was detected. On March 28th, 2023, the quality team went to investigate the assembly process. On March 28th, 2023, upon evaluating the process, an installation error was found that the index spring was installed in the incorrect position. On March 29th, 2023, the factory bike in question was disassembled and further investigated, providing confirmation of the incorrect index spring positioning. On April 3, 2023, the decision was made to conduct a recall to remedy this issue. Description of Remedy :
Description of Remedy Program : All motorcycles that have been manufactured by Buell Motorcycles, public
and internally, will have spring installed in the correct position. Some recall services will be completed at the Buell Factory, and some at certified service centers. The process of disassembly, index spring correction, and reassembly as well as the parts required will be provided to the service centers by Buell. How Remedy Component Differs from Recalled Component : The remedy component (spring) is the same as the recalled component – the remedy is to install the spring in the correct orientation. The index spring should be rotated clockwise and sit in the indented location. The difference will be an increased spring force applied to the index shim, allowing the bike to stay in gear and shift accordingly. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-257
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
The recall has been corrected in production April 3rd by updating the process sheet and providing visual aids to ensure proper installation going forward. Training will be completed to ensure proper placement. Recall Schedule :
Description of Recall Schedule : The initial letter to the owners as well as the dealers will be sent out
within the required 60-day time frame. The initial letters will be released to the dealers and owners on April 14 detailing the recall. There will be a subsequent letter to the owners to schedule their service followed by the process and required parts will then be sent to the service centers. .
Planned Dealer Notification Date : APR 14, 2023 – APR 28, 2023
Planned Owner Notification Date : APR 14, 2023 – APR 28, 2023
* NR – Not Reported

SEOCONTENT-END