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May 15, 2020 NHTSA CAMPAIGN NUMBER: 20V277000
Insufficiently Tightened Cylinder Head Nuts
A fouled spark plug could cause the engine to stall at idle and possibly not restart, increasing the risk of a crash.
NHTSA Campaign Number: 20V277
Manufacturer Yamaha
Motor Corporation, USA
Components ENGINE AND ENGINE COOLING
Potential Number of Units Affected 3,116
Summary
Yamaha Motor Corporation, USA (Yamaha) is recalling certain 2015-2018 XC155 scooters. The cylinder head nuts may not have been tightened properly and could loosen, allowing coolant to foul the spark plug.
Remedy
Yamaha will notify owners and dealers will replace the cylinder head gasket and tighten the cylinder head nuts, free of charge. The recall began May 29, 2020. Owners may contact Yamaha customer service at 1-800-962-7926. Yamaha’s number for this recall is 990137.
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.
| MOTORCYCLE | 5/29/2020 | M2020-005R |
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 2015~2018-MODEL XC155 (SMAX) SCOOTERS
FACTORY MODIFICATION CAMPAIGN – Coolant Enters the Combustion Chamber
INTRODUCTION
Yamaha Motor Corporation, U.S.A. has decided that a defect that relates to motor vehicle safety exists in certain 2015~2018-model XC155 scooters. In affected units, the cylinder head nuts may not have been tightened properly and could loosen, causing the cylinder head gasket to fail. If this happens, coolant might enter the combustion chamber and foul the spark plug, which could prevent the engine from starting, or the engine could stall at idle, which could result in a crash with injury or death.
To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected units must have the cylinder head gasket replaced and cylinder head nuts tightened properly per the Service Manual.
Yamaha is notifying all registered owners of affected scooters by U.S. mail. A copy of this letter is included in this bulletin. The customer should take this letter along with the affected scooter to an authorized Yamaha dealer for modification.
If your dealership was invoiced for one or more affected units, a computer report listing all affected scooters invoiced to your dealership is mailed with this bulletin. Use the list to help ensure all affected scooters are modified. All sold scooters that have been registered with Yamaha will show the customer’s name and address.
You must modify all affected scooters in your inventory as well as all customer-owned scooters brought to you for this service. If you purchase a scooter from another dealer or Yamaha, check to see if the procedures in this bulletin have already been performed before you sell the scooter.
Scooters 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 scooter to customers until the procedures in this bulletin are performed.
When the modification on each scooter 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 modified. If the unit is within the affected range and has not been modified, replace the cylinder head gasket with a new one, following the procedures in the Service Manual. |
| Parts: | Yes, replace the affected cylinder head gasket using the new cylinder head gasket kit. See the Parts Information section. |
| Warranty: | Factory Modification Campaign. See the Warranty Information section of this bulletin. modification applies to all affected units regardless of ownership or warranty status. |
| Notify Customers: | Yes, you must immediately contact any customer if a scooter shows as unregistered on the enclosed report. Yamaha has sent letters to customers whose scooters were registered with Yamaha as of 5/28/2020. |
AFFECTED RANGE
| Model | Model Year | Prefix | Primary ID | |
| From | To | |||
| XC155 | 2015 | SG30Y | 0001001 | 0003052 |
| XC155 | 2016~2018 | SG36Y | 0001001 | 0001673 |
IMPORTANT: Affected Primary IDs are not consecutive. Always check YDS Unit Status before starting any repair.
SERVICE PROCEDURES
Refer to the Service Manual (LIT-11616-28-47) as needed for replacing the cylinder head gasket.
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
| PART NUMBER | DESCRIPTION | QTY | DEALER COST |
| 90891-10293-00 | Cylinder Head Gasket Kit | 1 | $3.92 |
Kit Contents:
| REF. | DESCRIPTION | PART NUMBER |
| 1 | Cylinder Head Gasket Kit | 52S-E1193-01-00 |
| 2 | Gasket, Cylinder Head 1 | 52S-E1181-00-00 |
| 3 | Gasket, Cylinder | 52S-E1351-01-00 |
| 4 | O-Ring | 52S-E2439-00-00 |
| 5 | O-Ring | 93210-32807-00 |
| 6 | O-Ring | 52S-E2439-00-00 |
| 7 | O-Ring | 93210-347A1-00 |
| 8 | O-Ring | 1DK-E2843-00-00 |
| 9 | O-Ring | 4CW-E2223-00-00 |
| 10 | Gasket, Tensioner Case | 4DH-E2213-01-00 |
| 11 | Washer, Plate | 90201-08859-00 |
| 12 | Nut | 90179-08518-00 |
| 13 | Gasket, Exhaust Pipe | 5YP-E4613-00-00 |
| 14 | Washer, Plate | 90201-12172-00 |
| 15 | Gasket | 90430-06014-00 |
IMPORTANT:
Use the correct procedure for ordering warranty campaign parts (see Technical Bulletin MSA2017-001A).
WARRANTY INFORMATION
The owner of each registered scooter 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 scooters, 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 990137. The labor allowance is 2.6 hours, which includes reimbursement for coolant and other supplies.
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:
May 29, 2020
990137
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 2015~2018 XC155 (SMAX) scooters. Our records indicate that you own the affected scooter shown above.
| The reason for this recall: | In affected scooters, the cylinder head nuts may not have been tightened properly and could loosen, causing the cylinder head gasket to fail. If this happens, coolant might enter the combustion chamber and foul the spark plug, which could prevent the engine from starting, or the engine could stall at idle, which could result in a crash with injury or death. |
| What Yamaha and your dealer will do: | To correct this defect, your authorized Yamaha dealer will replace the cylinder head gasket and tighten the cylinder head nuts properly per the Service Manual. This procedure takes a little over 2½ hours to perform, but be aware that your Yamaha dealer may need to keep your scooter 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(s) performed. At that same time, you can find out how long they expect to keep your scooter to complete this service. Remember to take this letter with you when you take in your scooter.
Only ride your scooter to the dealership to be modified. You should avoid riding your affected scooter 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 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 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 Or call: 1-800-962-7926 If, after contacting Yamaha |
| If you no longer own this Yamaha: | If you have sold your scooter 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.
IMPORTANT SAFETY RECALL NOTICE
This notice applies to your vehicle, VIN xxxxxxxxxxxxxxxxx
Model:
May 29, 2020
990137
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 2015~2018 XC155 (SMAX) scooters. Our records indicate that you own the affected scooter shown above.
| The reason for this recall: | In affected scooters, the cylinder head nuts may not have been tightened properly and could loosen, causing the cylinder head gasket to fail. If this happens, coolant might enter the combustion chamber and foul the spark plug, which could prevent the engine from starting, or the engine could stall at idle, which could result in a crash with injury or death. |
| What Yamaha and your dealer will do: | To correct this defect, your authorized Yamaha dealer will replace the cylinder head gasket and tighten the cylinder head nuts properly per the Service Manual. This procedure takes a little over 2½ hours to perform, but be aware that your Yamaha dealer may need to keep your scooter 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(s) performed. At that same time, you can find out how long they expect to keep your scooter to complete this service. Remember to take this letter with you when you take in your scooter.
Only ride your scooter to the dealership to be modified. You should avoid riding your affected scooter 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 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 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 If, after contacting Yamaha |
| If you no longer own this Yamaha: | If you have sold your scooter 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.
May 15, 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 2015~2018 XC155 Scooters, 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.
- Manufacturers Name:
Yamaha Motor Taiwan Co., Ltd.
3, Chung Hua Rd., Sec. 2
Taoyuan City, 32068 Taiwan
Imported Vehicle Distributor:
Yamaha Motor Corporation, U.S.A.
6555 Katella Avenue
Cypress, California 90630
- Vehicles Affected: Make:
Model:
2015 ~2018 Model Year XC155 Scooters
Nominal Engine Displacement:
XC155 is 155cc
Production Period:
09/18/14 to 09/14/17
- The campaign relates to the Scooters Cooling system.
- Total number of subject vehicles: Current estimate: 3,116 units. This will be updated in a supplemental report as we finalize the affected VIN range.
- 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.
- The campaign involves the inspection and retorquing of cylinder head nuts. In affected Scooters, cylinder head nuts may not be properly toruqed. If this occures, there is a possibility for engine coolant to seep into the combustion chamber at low engine speeds which may cause the engine to stall and possibly 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.
- On May 11, 2020, Yamaha Motor Corporation, U.S.A. was informed by the manufacturer, Yamaha Motor Taiwan Co., 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 (a draft copy of the Customer Notification Letter has been provided via Agency Recall Portal), the affected VIN range is ascertained, and the Technical Bulletin with service procedures is confirmed and finalized by Yamaha service staff. Assuming the Agency can approve the letter within 5 days of receipt, (perhaps May 22nd) we will have the letter and the Technical Bulletin printed. Normal turn-around time is 3 working days for such printing. Hence the materials will be ready for mailing approximately May 28th. Final copies of these documents will be provided 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 & Certification
BRF/lf
cc:
By Recall portal
SEOCONTENT-START
6555 Katella Avenue • Cypress • California • 90630-5101 • (714) 761-7300 • Fax (714) 229-7944
May 15, 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 2015~2018 XC155 Scooters, 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 Taiwan Co., Ltd. 3, Chung Hua Rd., Sec. 2 Taoyuan City, 32068 Taiwan
Imported Vehicle Distributor: Yamaha Motor Corporation, U.S.A.
6555 Katella Avenue
Cypress, California 90630
2. Vehicles Affected: Make: Yamaha
Model: 2015 ~2018 Model Year XC155 Scooters
Nominal Engine Displacement: XC155 is 155cc
Production Period: 09/18/14 to 09/14/17
3. The campaign relates to the Scooters Cooling system.
4. Total number of subject vehicles: Current estimate: 3,116 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 retorquing of cylinder head nuts. In affected Scooters, cylinder head nuts may not be properly toruqed. If this occures, there is a possibility for engine coolant to seep into the combustion chamber at low engine speeds which may cause the engine to stall and possibly 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 May 11, 2020, Yamaha Motor Corporation, U.S.A. was informed by the manufacturer, Yamaha Motor Taiwan Co., 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 (a draft copy of the Customer Notification Letter has been provided via Agency Recall Portal), the affected VIN range is ascertained, and the Technical Bulletin with service procedures is confirmed and finalized by Yamaha service staff. Assuming the Agency can approve the letter within 5 days of receipt, (perhaps May 22nd) we will have the letter and the Technical Bulletin printed. Normal turn-around time is 3 working days for such printing. Hence the materials will be ready for mailing approximately May 28th. Final copies of these documents will be provided 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 & Certification
BRF/lf
cc: By Recall portal
4 Affected Products
Vehicles
9 Associated Documents
Miscellaneous Document – 573 Notifiction
RMISC-20V277-4736.pdf 101.408KB
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Defect Notice 573 Report
RCLRPT-20V277-4543.PDF 215.451KB
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Recall Acknowledgement
RCAK-20V277-6342.pdf 244.743KB
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Recall Quarterly Report #1, 2020-2
RCLQRT-20V277-0654.PDF 211.149KB
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ISSUED Owner Notification Letter(Part 577)
RCONL-20V277-7746.pdf 88.348KB
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Recall Quarterly Report #2, 2020-3
RCLQRT-20V277-8970.PDF 211.253KB
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Recall Quarterly Report #3, 2020-4
RCLQRT-20V277-1059.PDF 211.339KB
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Manufacturer Notices(to Dealers,etc) – 5/29/2020 M2020-005R
RCMN-20V277-0091.pdf 554.936KB
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Recall Quarterly Report #4, 2021-1
RCLQRT-20V277-2827.PDF 211.445KB
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