990136 – Improper Lubrication of Engine Components/Stall – 2019 Yamaha XV250 Motorcycles

April 9, 2020 NHTSA CAMPAIGN NUMBER: 20V212000

Improper Lubrication of Engine Components/Stall

Improper lubrication of internal engine components can result in the engine stalling, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V212

Manufacturer Yamaha Motor Corporation, USA

Components ENGINE

Potential Number of Units Affected 17

 

Summary

Yamaha Motor Corporation, USA (Yamaha) is recalling certain XV250 motorcycles. An oil passageway in the engine side cover may not be properly manufactured, possibly blocking lubricating oil to the engine.

 

Remedy

Yamaha will notify owners, and dealers will inspect and replace of the engine side cover, free of charge. The recall began April 17, 2020. Owners may contact Yamaha customer service at 1-800-962-7926. Yamaha’s number for this recall is 990136.

 

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

4/17/2020

M2020-003R

 

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.

 

CERTAIN 2019-MODEL XV250K1/K1C (V STAR 250)

FACTORY MODIFICATION CAMPAIGN – Improperly Machined Crankcase Cover Oil Passages

 

INTRODUCTION

Yamaha Motor Corporation, U.S.A. has decided that a defect that relates to motor vehicle safety exists in certain 2019-model XV250K1/ K1C (V Star 250) motorcycles. In affected units, an oil passageway in the engine side cover may not be properly machined. As a result, this could cause lack of proper lubrication resulting in severe engine damage that can cause the engine to stall and not restart again, resulting in the possibility of a crash with injury or death.

To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the engine crankcase cover 2 inspected for missing oil passageway holes in the oil filter mounting area. The crankcase cover 2 should be replaced if the holes are missing.

Yamaha is notifying all registered owners of affected motorcycles by U.S. 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 inspected and, if necessary, 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 inspection and, if necessary, 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 Unit Status in YDS to check to be sure that the unit is within the affected range and that it has not already been inspected. If the unit is within the affected range and has not been inspected, remove the oil filter and inspect if the oil passageway holes are present according to the Service Procedures in this bulletin. IMPORTANT: Pay close attention to the affected range. Only a very limited number of units are affected.
Parts:	No, unless the crankcase cover 2 is missing the oil passageway holes. If required, order a new crankcase cover 2. See the Parts Information section.
Warranty:	Factory Modification Campaign. See the Warranty Information section of this bulletin. This inspection and, if necessary, 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 4/16/2020.

 

AFFECTED RANGE

Model	Model Year	Prefix	Primary ID
			From	To
XV250K1	2019	VG04E	0020793	0020819
XV250K1C	2019	VG04Y	0002618	0002621

 

SERVICE PROCEDURES

Refer to the Service Manual (LIT-11616-XV-26) as needed for these procedures.

1. With the motorcycle on the side stand, remove the oil filter according to Service Manual instructions. Set the oil filter in a clean receptacle for reuse.
2. Inspect the oil filter cavity for two oil passageway holes.

If both holes are present, go to step 4 and submit a Recall claim for inspection only.

If one or both holes are missing, go to step 3 to replace the crankcase cover.

3. If one or both oil passageway holes are missing, replace the crankcase cover and cover gasket using the Service Manual procedures.
4. If the proper oil passageway holes are present, reinstall the oil filter and cover.

 

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

No parts are required unless the inspection shows that the necessary oil passageway holes were not present. If necessary, order a new crankcase cover 2:

PART NUMBER	DESCRIPTION	QTY	DEALER COST
2UJ-15421-00-00	Crankcase Cover 2	1	$153.68

 

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 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 modification or to file for reimbursement.

Submit a Recall Claim as described below using Campaign Number 990136 and choose either Inspected or Modified.

Inspected (The oil passageway holes were present) – Labor allowance is 0.2 hours.

Modified (The crankcase cover 2 was replaced) – Labor allowance is 0.4 hours.

YDS:

To submit your Recall Claim in the new 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).

 

IMPORTANT SAFETY RECALL NOTICE

This notice applies to your vehicle, VIN xxxxxxxxxxxxxxxxx

Model:

April 17, 2020 990136

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 XV250K1/K1C (V Star 250) motorcycles. Our records indicate that you own the affected motorcycle shown above.

The reason for this recall:	In affected units, an oil passageway in the engine side cover may not be properly machined. As a result, this could cause lack of proper lubrication resulting in severe engine damage that can cause the engine to stall and not restart again, resulting in the possibility of a crash with injury or death.
What Yamaha and your dealer will do:	To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the engine crankcase cover inspected by removing the oil filter. The procedure takes about xx minutes to do. Be aware that your Yamaha dealer may need to keep your motorcycle longer. If the cover was improperly machined, the cover must be replaced. This will take approximately xx minutes to perform. 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(s) performed. At that same time, you can find  out how long they expect to keep your motorcycle to complete this service. Remember to take this letter with you when you take in your motorcycle. Only ride your motorcycle to the dealership to be inspected. You should avoid riding your affected motorcycle shown above whenever possible until you can get it to the dealer to have this inspection and, if necessary, 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 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. 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: 1-800424-9153); or go to https://www.safercar.gov. Refer to NHTSA recall number 20V-112.
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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IMPORTANT SAFETY RECALL NOTICE

This notice applies to your vehicle, VIN  XXXXXXXXXXXXXXXXX   Model:

April 17, 2020

 

990136

 

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 XV250K1/K1C (V Star 250) motorcycles. Our records indicate that you own the affected motorcycle shown above.

The reason for this recall:	In affected units, an oil passageway in the engine side cover may not be properly machined. As a result, this could cause lack of proper lubrication resulting in severe engine damage that can cause the engine to stall and not restart again, resulting in the possibility of a crash with injury or death.
What Yamaha and your dealer will do:	To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the engine crankcase cover inspected by removing the oil filter. The procedure takes about 12 minutes to do. Be aware that your Yamaha dealer may need to keep your motorcycle longer. If the cover was improperly machined, the cover must be replaced. This will take approximately 24 minutes to perform. 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(s) performed. At that same time, you can find out how long they expect to keep your motorcycle to complete this service. Remember to take this letter with you when you take in your motorcycle. Only ride your motorcycle to the dealership to be inspected. You should avoid riding your affected motorcycle shown above whenever possible until you can get it to the dealer to have this inspection and, if necessary, 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 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 20V-112.
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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April 08, 2020

 

Chief Administrator
National Highway Traffic Safety Administration
Associate Administrator for Safety Assurance (NVS-215)
1200 New Jersey Avenue SE,
Washington, DC  20590

 

Regarding: Yamaha Model Year 2019 XV250 Motorcycles, Factory Modification Campaign.

 

Dear Sir/Madam:

The purpose of this correspondence is to provide preliminary information required by 49 CFR 573 and the National Traffic and Motor Vehicle Safety Act regarding a defect notification campaign we are initiating.  Attached are draft copies of the Owner’s notification letter, for Agency approval, and the dealer technical bulletin. The envelope format and label has previously been approved by the Agency for prior campaigns.

 

1. Manufacturers Name:

Yamaha Motor Company, Ltd.
2500 Shingai
Iwata, Japan

Imported Vehicle Distributor:

Yamaha Motor Corporation, U.S.A.
6555 Katella Avenue
Cypress, California 90630

 

2. Vehicles Affected:

Make:
Yamaha

Model:
2019 Model Year XV250 Motorcycles

Nominal Engine Displacement:
XV250 is 250cc

Production Period:
12/19/18 to 01/1019

 

3. The campaign relates to the motorcycle’s Lubrication system.

 

4. Total number of subject vehicles: Current estimate: 17 units.  This will be updated in a supplemental report as we finalize the affected VIN range.

 

5. VIN Range: Tentative range will be supplied in forthcoming draft Technical Bulletin. Likewise, this will be updated in a subsequent report as data is confirmed.

 

6. The campaign involves the inspection and replacement of the engine side cover. In affected motorcycles, an oil passageway may not be properly machined. If this happens, there is a possibility for improper lubrication of internal engine components, as a result, improper lubrication may cause the engine to stall and may not restart. These conditions could result in the possibility of a crash with injury or death. Please refer to the draft Technical Bulletin which will be furnished to the Agency and Yamaha dealers upon completion describing the situation which is the subject of the campaign.

 

7. On March 30, 2020, Yamaha Motor Corporation, U.S.A. was informed by the manufacturer, Yamaha Motor Company, Ltd., that such a situation exists. This was determined pursuant to a quality control review, testing and a review of models that use a substantially similarly part design.

 

We anticipate commencing dealer/owner notification shortly after the owner’s notification letter is approved by NHTSA (draft copies of the Customer Notification Letter and Technical Bulletin is attached for your review), the affected VIN range is ascertained, and the Technical Bulletin service procedure is confirmed and finalized by Yamaha service staff.  Assuming the Agency can approve the letter within 7 days of receipt (perhaps April 15) we will have the letter and Technical Bulletin printed.  Normal turn-around time is 3 working days for such printing. Hence the materials will be ready for mailing approximately April 17th.  Final copies of these notification documents will be forwarded to the Agency as soon as possible.

 

In the event we can answer any questions or provide supplemental information, please do not hesitate to contact me.  My direct telephone number is 714-761-7842.  The fax number is 714-229-7944.  My email is brad_franklin@yamaha-motor.com.

 

Sincerely,

 

Bradley Franklin

Bradley Franklin
Manager, Government Relations

 

BRF/lf

cc:By Recall portal
Defects & Recall Information Analysis Division

 

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1 Affected Product

Vehicle

MAKE	MODEL	YEAR
YAMAHA	XV250	2019

 

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9 Associated Documents

Miscellaneous Document – Initial NHTSA notification report

RMISC-20V212-9676.pdf 100.461KB

 

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Recall Acknowledgement

RCAK-20V212-6176.pdf 244.225KB

 

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Defect Notice 573 Report

RCLRPT-20V212-8475.PDF 216.135KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V212-9958.pdf 139.019KB

 

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V212-5346.PDF 211.14KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V212-5811.PDF 211.242KB

 

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V212-5571.PDF 211.331KB

 

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Manufacturer Notices(to Dealers,etc) – 4/17/2020 M2020-003R

RCMN-20V212-4006.pdf 660.986KB

 

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Recall Quarterly Report #4, 2021-1

RCLQRT-20V212-5043.PDF 211.433KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V212&docType=RCL

 

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