Front Brake Lever May Break – 2019 Yamaha YZFR3 Motorcycles

May 2, 2019 NHTSA CAMPAIGN NUMBER: 19V341000

Front Brake Lever May Break

A broken front brake lever can affect front braking ability, increasing the risk of crash.

 

NHTSA Campaign Number: 19V341

Manufacturer Yamaha Motor Corporation, USA

Components SERVICE BRAKES

Potential Number of Units Affected 198

 

Summary

Yamaha Motor Corporation, USA (Yamaha) is recalling certain 2019 YZFR3 motorcycles. Porosities in the front brake lever may cause it to break if it is gripped with a strong force.

 

Remedy

Yamaha will notify owners, and dealers will inspect and replace the front brake lever, as necessary, free of charge. The recall began May 15, 2019. Owners may contact Yamaha customer service at 1-800-962-7926. Yamaha’s number for this recall is 990128.

 

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

5/15/2019

M2019-002R

 

CERTAIN 2019 YZFR3K (“YZF-R3”) AND YZFR3AK (“YZF-R3 ABS”) MODELS FACTORY MODIFICATION CAMPAIGN – Front Brake Lever

INTRODUCTION

 

Yamaha Motor Corporation, U.S.A. has decided that a defect which relates to motor vehicle safety exists in certain 2019 YZFR3K (“YZF-R3”) and YZFR3AK (“YZF-R3 ABS”) motorcycles. In affected units, there is the potential for the front brake lever to have been manufactured with porosities in the material. Porosities in the material could allow the lever to break while applying a strong gripping force. A broken lever could cause sudden loss of front braking ability and a crash with injury or death.

To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the brake lever (Lever 2) inspected and, if found to have an affected manufacturing code as described in this bulletin, replaced with a new one that was manufactured correctly.

Yamaha is notifying all registered owners of affected motorcycles by US 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 inspect and, if necessary, 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, and then inspect the stamped manufacturing code on the underside of the brake lever as instructed in this bulletin. If the lever has an affected manufacturing code, replace the lever with a new one.
Parts:	Yes, but only if inspection shows that the brake lever is stamped with one of the affected manufacturing codes. 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 5/14/2019.

 

AFFECTED RANGE

Model			Model Code	Primary ID
				Prefix	From	To
2019 YZF-R3			B8P1	RH17Y	0002641	0002720
2019 YZF-R3A			B5L2	RH18Y	0002241	0002440

 

SERVICE PROCEDURES

Inspection

Inspect the stamped manufacturing code on the underside of the front brake lever. If the brake lever has stamping code K3 9A 16 or K4 9A 16 (shown), replace it with a new one.

Important:

If an affected motorcycle has the accessory Yamaha R3 Brake Lever (1 WD-H39A0-V0-00) or another aftermarket brake lever, confirm whether or not your dealership or the customer retained the stock brake lever. If so, inspect it according to these bulletin instructions.

Replacement

If the lever has stamped code K3 9A 16 or K4 9A 16, refer to the Service Manual (YZFR3K: LIT-11616-28-57 or YZFR3AK: LIT-11616-30-55) to replace the front brake lever (Lever 2). Discard or recycle the brake lever so it cannot be accidentally reused.

 

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 units repair history in Yamaha’s database.

 

PARTS INFORMATION

Order a replacement brake lever for each affected unit if that has an affected manufacturing code on the original lever.

Part Number				Kit Part Name	Dealer Cost
IWD-H3922-OO-OO				LEVER 2 (BRAKE LEVER)	$11 .52

 

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 inspection and, if necessary, 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 inspection/ modification or to file for reimbursement.

Submit a Recall Claim as described below using Campaign Number 990128 and choose either Inspected or Modified. The labor allowance is 0.2 hour for either inspection or inspection and modification.

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.

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:

May 15, 2019

 

990128

 

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 YZFR3K (“YZF‐R3”) and YZFR3AK (“YZF‐R3 ABS”) motorcycles. Our records indicate that you own the affected motorcycle shown above.

The reason for this recall:	In affected motorcycles, there is the potential for the front brake lever to have been manufactured with porosities in the material. Porosities in the material could allow the lever to break while applying a strong gripping force. A broken lever could cause sudden loss of front braking ability and a crash with injury or death.
What Yamaha and your dealer will do:	To correct this defect, your authorized Yamaha dealer will inspect the front brake lever to see if it has a manufacturing date code that identifies it as possibly being defective due to porosities in the material. If so, they will replace the front brake lever with a new one. The procedure takes about 15 minutes to do, but be aware that your Yamaha dealer may need to keep your motorcycle 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 the procedure performed. At that same time, you can find out how long they expect to keep your motorcycle to complete this safety recall. 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 your affected motorcycle has the accessory Yamaha R3 Brake Lever (part number 1WD‐H39A0‐V0‐00) or another aftermarket brake lever installed, and you retained the original lever, please have your dealer inspect it and replace it if needed. If you discarded the original front brake lever, please contact Yamaha Customer Relations as indicated below to let us know that the recall does not apply to you. 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: 1‐800‐4249153); or go to https://www.safercar.gov. Refer to NHTSA recall number 19V341.
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

YAMAHA

YZFR3

2019

 

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8 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-19V341-9617.pdf 157.881KB

 

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Recall Acknowledgement

RCAK-19V341-5517.pdf 246.309KB

 

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Miscellaneous Document – Defect Information Report

RMISC-19V341-5161.pdf 286.954KB

 

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Defect Notice 573 Report

RCLRPT-19V341-5656.PDF 214.446KB

 

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Remedy Instructions and TSB

RCRIT-19V341-0988.pdf 974.527KB

 

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Recall Quarterly Report #3, 2019-4

RCLQRT-19V341-4582.PDF 211.318KB

 

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Recall Quarterly Report #1, 2019-2

RCLQRT-19V341-3750.PDF 211.135KB

 

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Recall Quarterly Report #2, 2019-3

RCLQRT-19V341-5130.PDF 211.23KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V341&docType=RCL

 

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