2023-10 – High-Pressure Fuel Pump May Fail – 2019-2023 Can-Am Ryker Motorcycles

December 15, 2023 NHTSA CAMPAIGN NUMBER: 23V855000

High-Pressure Fuel Pump May Fail

A fuel pump failure can cause an engine stall while driving, increasing the risk of a crash.

 

NHTSA Campaign Number: 23V855000

Manufacturer Bombardier Recreational Products, Inc.

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 10,969

 

Summary

Bombardier Recreational Products, Inc. (Bombardier) is recalling certain 2019-2023 Can-Am Ryker motorcycles. The impeller may swell, causing the high-pressure fuel pump to fail.

 

Remedy

Dealers will inspect and replace the fuel pump as necessary, free of charge. Owner notification letters are expected to be mailed January 22, 2024. Owners may contact Bombardier customer service at 1-888-272-9222. Bombardier’s number for this recall is Bulletin 2023-10.

 

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.nhtsa.gov.

 

Check for Can-Am Recalls

 


No. 2023-10

December 21, 2023

Fuel Pump – Potential Loss of Propulsion

 

What should you do?

–Do not sell or deliver any involved vehicle that you have in stock as federal law requires you to complete the recall service on these vehicles before retail delivery.

–Unregistered vehicles cannot be sold until the campaign is performed.

–Contact all of your customers who purchased an affected vehicle or a service part and inform them aboutthis Safety Recall notice.

 

PROBLEM

The fuel pump impeller could swell and cause the fuel pump to stop working. This could lead to an engine stall while driving without the ability to restart the vehicle. This situation may increase the risk of a crash.

 

SOLUTION

Inspect first 3 digits of the serial number on the fuel pump and replace fuel pump if number is included in campaign.

 

REQUIRED PARTS

DESCRIPTION PART NUMBER QTY
Fuel pump* 709001261 for MY21 to MY24

** 219800529 retrofit for MY19 –MY20

1
Sealing ring7090002081
Oetiker Clamp2936500471

* Use 709001261 to replace a defective 709000810 and 709001261, WITHOUT ground terminal.
** Use 219800529 to replace a defective 219800529 and 548874036, WITH ground terminal.

WARNING

If a ground wire is present, it is important to install a fuel pump model having the same connector. Ensure proper connection to avoid electrical static discharge.

 

Inspection Procedure

Reading Serial number

1. Remove fuel tank cover.

The fuel pump serial number is located at two different locations; on a label and engraved on the fuel pump top flange.

The fuel pumps affected have a serial number within this inclusive range:

079XXX XXXX to 176XXX XXXX

 

Proceed in the following order:

Label on Fuel Pump is Possible to Read

1. Clean upper section of fuel pump to read label.

NOTICE

Use a clean rag, do not use any solvents.

2. If first 3 digits are included in the list of affected fuel pumps, proceed with FUEL PUMP REPLACEMENT.

 

Label on Fuel Pump is Impossible to Read

1. Depressurize fuel pump. Refer to FUEL PUMP DEPRESSURIZATION.

2. Remove fuel pump locking ring.

3. Read the first 3 digits of the serial number that are engraved on top of fuel pump flange, as shown on item 2 of image above.

4. If first 3 digits are included in the list of affected fuel pumps, proceed with FUEL PUMP REPLACEMENT.

5. Otherwise, remove and reinstall pump with a NEW sealing ring. Refer to FUEL PUMP REPLACEMENT for installation instructions.

 

Fuel Pump Depressurization

NOTE: Before starting fuel pump depressurization, ensure the fuel gauge level reading is below 9 bars over 10.

 

If the level displayed is FULL (10/10), siphon 1.6 Gallons (6 liters) of fuel in a clean container. The fuel will be refilled in the fuel tank at the end of the procedure.

It is recommended to depressurize the fuel system before disconnecting fuel hoses.

1. Disconnect fuel pump connector.

2. Start and idle engine.

3. Allow the engine to stall.

4. Remove and discard Oetiker clamp and disconnect pressure hose. Use a clean rag to avoid any fuel spillage.

 

Fuel Pump Replacement

1. Depressurize fuel system. Refer to FUEL PUMP DEPRESSURIZATION.

2. While holding the fuel pump flange, remove fuel pump locking ring.

Fuel Pump Nut Tool (P/N 529035899)

3. Remove and discard seal.

4. Carefully pull out fuel pump paying attention to float arm.

NOTICE

Manipulate fuel pump with care.

5. Wipe off any fuel residue in the sealing area.

6. Install a NEW sealing ring on fuel pump flange.

NOTE: To ease proper sealing between pump and fuel tank, install sealing ring on the fuel pump flange before lowering pump in place.

WARNING

If a ground wire is present, it is important to install a fuel pump model having the same connector. Ensure proper connection to avoid electrical static discharge.

7. Connect ground connector if applicable.

8. Ensure the fuel pump motor is fully toward the front of the vehicle to ensure proper fuel float movement.

NOTICE

Strictly orient the fuel pump as indicated. Damage to the fuel level connection or to the float may occur.

9. When lowering pump into position, ensure the angle is in line with the fuel tank flange. The pump flange should lie flat on the fuel tank. Seal should be properly seated all around flange.

10. Pay attention to pump orientation as in following illustration.

NOTE: Make sure arrow on fuel pump points toward the first line on fuel tank.

11. Insert fuel pump locking ring.

12. While firmly holding pump down against tank, engage fuel pump locking ring on fuel tank flange.

CAUTION

Be careful not to cross thread the locking ring onto the fuel tank. This may lead to a fuel leak.

13. Tighten locking ring to specification.

TIGHTENING TORQUE

Fuel pump locking ring

29 ± 1 N•m
(21 ± 1 lbf•ft)

NOTE: Make sure the pump body has not rotated excessively during nut tightening procedure.

14. When finishing the tightening sequence ensure the pump is still oriented between the two lines.

WARNING

If fuel pump is not properly aligned, the fuel level sensor could touch the side walls of the tank causing inaccurate reading that may lead to vehicle running out of gas.

15. Install fuel pressure hose with NEW Oetiker clamp.

16. Connect fuel pump connector.

17. Start the vehicle, verify engine is running normally, and inspect there is no fuel leak.

18. Reinstall all removed components. Installation is the reverse of the removal procedure.

 

 


Chronology :

In August 2023, Transport Canada informed BRP of received reports of fuel pumps malfunction. The cases were grouped under TC 3208-07-52.

BRP reviewed all the TC reports, reanalyzed its network data, contacted customers, and collected fuel pumps from the field. BRP also promptly contacted its fuel pump supplier to start a joint analysis. The investigation took place from August to December 2023. During this time, BRP was informed by its supplier that changes were made as to the source of the raw material used to produce the impeller over the years (initial source, new source and back to the initial source). It was found that the “new” source of material for the impeller could cause it to swell and come in interference with the housing. This could create a fuel pump failure. BRP worked to confirm its supplier’s findings and to identify when those fuel pumps were installed on its vehicles and sold as service parts.

BRP was also contacted by NHTSA during this period following reports from customers as well.

With all the information collected and analyzed, BRP decided on December 11, 2023, that it had enough information to report and wants to proceed with a safety recall.

In looking back in its claim data and after reanalysis, BRP evaluates that in the United States, 132 cases could be potentially related to this situation from which 43 occurring while riding with a reported failure date after the cut off date of March, 6, 2021 to October 30, 2023.

No accident was reported worldwide.

 


5 Affected Products

Vehicle

MAKEMODELYEAR
CAN-AMRYKER2019-2023

 


5 Associated Documents

Defect Notice 573 Report

RCLRPT-23V855-3267.PDF 222.507KB

 


Recall Acknowledgement

RCAK-23V855-9712.pdf 645.397KB

 


Manufacturer Reimbursement Plan

RMRP-23V855-9399.pdf 69.798KB

 


Manufacturer Notices(to Dealers,etc)

RCMN-23V855-6433.pdf 697.217KB

 


Safety Bulletin

RCSB-23V855-7895.pdf 1339.021KB

 


Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

 


 

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