Ignition Switch Inspection/Replacement
Contents
1. CUSTOMER NOTIFICATION LETTER Page Two of Two How do I receive the fastest possible service cont When you pick up your repaired motorcycle please allow a few extra minutes for your dealer to prepare and complete the necessary warranty paperwork with you If you have special circumstances discuss them with your Suzuki dealer Suzuki understands that some customers may have difficult circumstances to overcome in bringing their motorcycle to the dealership for repair We have asked your Suzuki dealer to work closely and flexibly with you to arrange alternative but reasonable solutions for your special requests Please remember however that each dealership has its own limitations in providing special assistance due to staff size available time and dealership location Your dealer can also consult with Suzuki on other alternatives Questions amp Answers Your Suzuki dealer has been provided specific and complete instructions regarding this recall service Please call your dealer if you have any questions Your local Suzuki dealer can provide the fastest responses to your questions or concerns about the recall service Your dealer can also contact Suzuki on your behalf if you have a unique question or concern If you have difficulty having the recall service performed on your motorcycle you may contact the American Suzuki Customer Service Department for assistance at 1 714 572 1490 You will need to have your Vehicle Identification Number read2. SUZUKI Service Bulletin MOTORCYCLE ATV DIVISION 4 STROKE GS GSX GSX R BULLETIN NO 183 DATE 6 6 2008 SAFETY RECALL CAMPAIGN 2A05 CERTAIN 2008 GSX1300RK8 MOTORCYCLES IGNITION SWITCH INSPECTION REPLACEMENT SUBJECT RECALL CAMPAIGN IGNITION SWITCH INSPECTION REPLACEMENT AFFECTED UNITS CERTAIN 2008 GSX1300RK8 MOTORCYCLES REFERENCE GSX1300R SERVICE MANUAL PN 99500 39350 03E ATTACHMENT CUSTOMERETTER WHAT IS THE PROBLEM This notice is sent to youwin accordance with the requirements of the National Traffic and Motor Vehicle SafetypaAct Suzuki Motor Corporation has determined that certain GSX1300ORK8 motorcycles may have the ignition Switch lead wire improperly routed Handlebar movement can result in abnormal flexing and damage to thefignition switch lead wire Damage to the ignition switch lead wire can result in intermittent orycomplete loss of electrical power which can result in loss of lighting and or stalling of the engine This could result in a crash STOP DELIVERY OF 2008 GSX1300RK8 MOTORCYCLES IMMEDIATELY DO NOT DELIVER an affected NEW or USED 2008 GSX1300RK8 motorcycle to a customer until you have completed or verified completion of the procedures in this bulletin It is a violation of Federal law to deliver any new vehicle subject to a safety recall campaign under a sale or lease until the defect or noncompliance has been corrected You must verify this on the Suzuki Certificate of Vehicle Pre Del
3. you will see the message CAMPAIGN NOF YET PERFORMED displayed and the ignition switch lead wire routing will need to be inspected Refer to the inspection procedure in this bulletin 2 Inspect the right side of the frame head tube for an identification punch mark located at the beginning of the Vehicle Identification Number If a punch mark is presentthe recall repair has already been performed Punch mark 4 e JS1GX72A382100028 WHAT YOUR DEALERSHIP WILL DO Notify your staff Contact your customers please telephone all of your customers and inform them of the need to stop riding their motorcycles until the ignition switch lead wire inspection replacement has been completed NOTE If your dealership has sold an affected GSX1300RK68 to a customer but you have not yet submitted sales registration entry send the sales information to American Suzuki AT ONCE We will send the customer an owner notification letter when we receive the sales information from your dealership Since only you know the identity of these customers you must immediately notify these customers of the recall campaign 2 12 CUSTOMER NOTIFICATION In the Safety Recall Campaign letter that will be mailed on June 10 2008 see attachment customers are being advised to contact the Suzuki dealer where they purchased their affected unit to schedule an appointment to have the ignition switch lead wire inspected As some customers may have moved to other c
4. roove at a 90 angle to the original groove A CAUTION When striking an object with a hammer parts can fly up hitting you in the eyes and cause blindness or injury Always wear eye protection when us ing a hammer 4 Remove the ignition switch from the vise and hold it upright over the workbench and carefully remove the cylinder cap Figure 8 NOTE Pay close attention to the order and orientation of the ignition switch parts during disassembly 6 12 5 Remove the shutter The shutter may come off the ignition switch in the cylin der cap but is not secured to the cap Remove the rotor and spring from the ignition switch When the rotor is re moved the spring may be attached to the rotor but it will not be secured The cylinder cap shutter rotor and spring will be used for reassembly of the new switch Keep these parts in a safe clean location Attach a warranty parts tag to the origi nal ignition switch body and retain for TSM inspection New Ignition Switch Disassembly 6 Using a philips screwdriver carefully remove the break off screws from the new ignition switch these screws are hand tightened and keep them for reas sembly of the new ignition switch 7 Remove the cylinder cap shutter rotor and spring These parts will not bere for reassembly of the new we New Ignition Switch Reasse Begin reassembly usi In o of the new ignition S e new recall kit ignition swi v can
5. stalling of theeengine This could result in crash AWARNING To minimize the risk of injury or death we recommend that you do not ride or allow anyone else to ride your 2008 model year GSX1300RK8 Hayabusa until your motorcycle has been repaired by your Suzuki dealer Suzuki strongly recommends that you do not ride your affected 2008 GSX1300RK8 Hayabusa motorcycle until the ignition switch inspection replacement has been completed What is Suzuki doing to solve the problem The repair consists of thoroughly inspecting the ignition switch lead wire routing If the ignition switch lead wire is not routed or clamped properly Suzuki will replace the ignition switch lead wire assembly Your original lock set will be installed onto the new ignition switch lead wire assembly so that your original key will operate the ignition switch Repair time is approximately 1 3 hours and will be performed at no cost to you for parts or labor How do receive the fastest possible service Suzuki understands that your riding time is precious Our suggestion is to work closely with your authorized dealer to get the recall service scheduled and performed on your motorcycle as quickly as possible Schedule an appointment for the recall service to be performed Parts are currently available It will be necessary for your dealer to order the parts It may be necessary to leave your motorcycle with the dealer overnight so check with your dealer 11 12
6. additional time orparts required as approved by Tech Line Labor time is 1 3 hours RECALL CAMPAIGN IGNITION SWITCH LEAD WIRE INSPECTION AND REPLACEMENT Long Form Instructions GENERAL CLAIM NUMBER XXXXX X Dealer enters number ENTRY TYPE Model Frame or Control Sequence Dealer Chooses MODEL GSX1300RK8 FRAME X821XXXXX REPAIR DATE Enter date of repair MILEAGE Enter mileage on unit CAMPAIGN NUMBER 2A05 LABOR HOURS 1 3 hrs PARTS REPLACEMENT PART NUMBER 99103 11237 OTY 1 FAILURE DESCRIPTION DESCRIPTION OF FAILURE Replace Ignition Switch Assembly per Service Bulletin GS GSX GSXR GSF 183 SUBLET SUBLET AMOUNT as approved by TECH LINE NOTE Do not use the when entering an amount SUBLET REFERENCE NUMBER 2A05 SUBLET REPAIR DESCRIPTION Suzuki Connect Long Form warranty claim entries with additional parts or labor require a prior authorization PAS code from TECH LINE or your Technical Service Manager or the Suzuki Connect system will not accept the claim 9 12 CUSTOMER SATISFACTION We understand and apologize for any inconvenience this recall campaign may cause you or your customers Thank you for your cooperation in conducting this very important campaign for your customers safety and satisfaction Only your conscientious action at the dealership level can lead to a successful campaign conclusion Please remind your staff to be sympathetic and sensitive to your customers feelings Please extend Su
7. be identified by the le at the end of th en nu IA 10 8 A e spring from t M switch onto the proj the new ignition switch body Figure 11 9 Install the rotor from the original ignition switch into the new ignition switch body There is only one correct position Figure 12 to install the rotor into the ignition Tumbler Plates switch body Note the position of the tumbler plates when the rotor is installed When installed in the correct position the rotor will drop into the new ignition switch body smoothly and easily Do not force or push the rotor into the ignition switch or damage may occur 10 11 12 13 Place the shutter from the original igni tion switch on the rotor aligning and placing the projections into the hollows Figure 13 The shutter can be aligned one of two ways 180 apart Either way IS correct Place the cylinder cap over the key cylinder and hold it firmly in position Insert the ignition key and test the rota tion of the rotor If the rotor does not turn smoothly remove the cap and check the assembly making any necessary correc tions Repeat the procedure until the rotor turns smoothly when using the key Secure the cylinder cap with the break off screws Tighten the screws evenly until the screw heads break off Figure 14 Install the plastic caps provided in the kit on the cylinder cap over the break off screws Install the ignit
8. hipped separately at no cost to yourdealership during the week of June 9 2008 IGNITION SWITCH LEAD WIRE INSPECTION REROUTING OR REPLACEMENT STEPS New Unsold Unit Dealer Inventory Inspect Routing page 4 OK gt Punch Mark VIN page 8 Incorrect LC Reroute page 5 OK gt Punch Mark VIN page 8 Customer Unit Sold Dealer Demo Unit Inspect Routing page 4 OK gt Punch Mark VIN page 8 Incorrect E l Replace Ignition Switch OK Punch Mark VIN page 8 page 6 3 12 INSPECT ROUTING 1 Remove the upper and lower meter panels refer to Service Manual page 9D 15 2 Check if the ignition switch lead wire is clamped and routed correctly Incorrect positions are shown in Figures 1 and 2 Correct routing and clamping is shown in Figures 3 and 4 on page D ncorrect Gray Tape Position Gray tape is not visible on both sides of clamp Or Gray tape is not positioned beneath clamp Incorrect Routing Ignition switch harness is routed behind the right switch harness Cowling Brace Side yy 90 E _ f ETN i F hy i ma Pa a i 4 Y s b pa na a 1 p ae ay i a ee ch it SI laa Ignition Switch Lead Wire 4 12 Correct Routing The ignition switch lead wire is routed in front of the right switch lead wire HANDLE SWITCH LEAD WIRE Correct Gray Tape Location Gray tape is visible on both sides of clamp REROUTING 1 Reroute
9. ion switch assembly refer to Service Manual page 1H 12 Be cer g tain to use the pre coated bolts ignition switch 0 ignition Switch ary 30 ts SS wire Turn the A verify that the steering operatesssmot and the wiring harness does not get kinked or pinched PUNCH MARK AT VIN 1 After the inspection rerouting or re placement procedure is complete be cer tain to place an identification punch mark on the frame at the beginning of the Vehicle Identification Number located at the right side of the frame head tube as illustrated on page 2 8 12 WARRANTY REIMBURSEMENT amp CLAIM INFORMATION Submit a warranty claim for each recall campaign service immediately upon completion of the repair This campaign requires you to file a warranty claim using the following information Short Form Claim Use the Short Form Claim for new and customer owned units that require ignition switch lead wire inspection and or re routing Labor time is 0 3 hours RECALL CAMPAIGN IGNITION SWITCH LEAD WIRE INSPECTION REROUTE Short Form Instructions GENERAL CLAIM NUMBER XXXXX X Dealer enters number ENTRY TYPE Model Frame or Control Sequence Dealer Chooses MODEL GSX1300RK8 FRAME X821XXXXX REPAIR DATE Enter date of repair MILEAGE Enter mileage on unit CAMPAIGN NUMBER 2A05 Long Form Claim Use the Long Form Claim for customer owned eunitswrequiring ignition switch assembly replacement or for units with
10. ivery form which is to be completed for all new and used vehicle sales WHAT WILL SUZUKI DO Suzuki is recalling affected units for inspection of the ignition switch lead wire routing You will correctly reroute or replace the ignition switch lead wire portion of the ignition switch assembly Instructions are provided in this bulletin for correct routing and replacement of the ignition switch lead wire to prevent failure 1 12 AFFECTED UNIT VIN RANGES The VIN ranges of the affected GSX1300RK8 models are listed below Confirmation of an affected unit can be checked on Suzuki Connect Starting VIN Ending VIN JS1GX 2A 82100020 JS1GX72A 82111031 JS1GX7 2A 82111267 n a JS1GX7 2A 82111546 JS1GX72A 82111605 JS1GX7 2A 82111700 n a JS1GX7 2A 82111726 JS1GX7 72A 82111753 JS1GX7 2A 82111755 JS1GX72A 82111756 JS1GX7 2A 82111759 a JS1GX7 2A 82111 766 JS1GX7 72A 82111773 JS1GX7 2A 82111775 JS1GX7 2A 82111785 JS1GX7 2A 82111945 JS1GX7 72A 82112169 JS1GX7 72A 82112171 JS1GX72A 8211 1948 JS1GX72A 82142167 J51GX72A 82111759 n D gt b S S Q Q JS1GX72A 82112289 VERIFY THE UNIT REQUIRES THE RECALL REPAIR Before performing the recall inspection toa unit verify that thedmspection needs to be done There are two ways to identify a unit that has already b en repaired 1 Check the repair status by gt checking the Vehicle History in the Suzuki Connect Service Menu If the repaimneeds to be performed to theymotorcycle
11. letter sent by Suzuki e Reimbursement claims may also be excluded when you do not submit adequate documen tation Your authorized Suzuki dealer will request an original or copy of your receipt for the recall repair or replacement and your owner notification letter To obtain information or request reimbursement contact your Suzuki dealer or the American Suzuki Motor Corporation Motorcycle Customer Service Department PO Box 1100 Brea CA 92822 1100 or call 1 714 572 1490 You will need to have your Vehicle Identification Number ready when calling We thank you for your prompt attention to completing this recall service on your Suzuki motorcycle We apologize for any inconvenience this campaign causes you Your safety satisfaction and riding enjoyment are priorities for Suzuki Sincerely American Suzuki Motor Corporation 12 12
12. ommunities since their motorcycle purchase you may also receive calls from customers who purchased their Suzuki elsewhere Once you are contacted by the owner of an affected unit please arrange an appointment for a recall inspection Also advise your customers that the Safety Recall Campaign service will be performed at no cost to them for parts and labor IMPORTANT Successful completion of this safety recall campaign depends on your efforts It is your responsibility to repair any affected GSX1300RK8 within the VIN range at no cost to the customer for recall service parts and labor Incidental costs your customers may incur are not normally covered However if you have a customer with special needs contact your Technical Service Manager 800 756 3251 to discuss possible solutions ORDERING PARTS FOR THE SAFETY RECALL CAMPAIGN You will be responsible for ordering the ignition switch kit for any customer s motorcycle which had an incorrectly routed ignition switch lead wire Ord r the switch kit using your normal parts ordering methods New unsold unitseat your dealership will not require a replacement ignition switch kit Parts are currently available for this campaign Ignition Switch Set PN 99403 11237 Dealer Cost 85 03 Oty Note Ignition Switch Mounted on Ignition Switch 3 Bolt MS 2 Tormx head Pre coated bolt o SPECIAL TOOL AUTO SHIPMENT The special tool needed to disassemble the lock cylinder assembly will be auto s
13. the ignition switch lead wire correctly Figure 3 and Figure 4 The ignition switch lead wire should not be covered by the other wire harnesses 2 Turn the handlebars back and forth to verify that the steering operates smoothly and the wiring harness does not become kinked or pinched 3 Proceed to PUNCH MARK AT VIN on page 8 5 12 REPLACEMENT OF IGNITION SWITCH Customer Sold Units Dealer Demo Units Only If Inspection Shows Incorrect Routing And Unit Has Been Ridden New Ignition Switch Disassembly 1 Remove the ignition switch assembly from the motorcycle refer to Service Manual page 1H 12 2 Remove the two black plastic covers to access the cylinder cap mounting bolts Figure 5 Note The black plastic covers will not be reused 3 Secure the mount area bottom of the ignition switch in a vise Figure 6 NOTE Turn the ignition switch to the OFF posi tion and remove the key from the ignition switch before disassembling the switch Tor Remove the two break off screws from the ignition switch using the special screwdriver Set the stepped end of the sleeve on the special screwdriver facing toward the break off s ws Figure 7 Strike the special scr r 5 to 7 times with a hamm uce a deep enough groove o rew head for the screwdriver ork properly Figure 6 P aan not to hit other parts wit r Turn to remo CS the brea screws In a co clockwise irection If the comes damaged make anot
14. y when calling If you believe that 1 Suzuki or your Suzuki dealer has failed to or is unabletto perform the recall service without charge or 2 you believe Suzuki has failed to or is unable to perform the recall procedure to your vehicle within 60 days after you first brought yourgvehicle to your Suzuki dealer after June 10 2008 you may submit a complaint to the Administrator National Highway Traffic Safety Administration 1200 New Jersey Ave S E West Building Washington D C 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 Locating an alternate dealer Suzuki dealers can be located on the internet at www suzukicycles com or_by Calling 1 800 828 7433 Customer Reimbursement If your motorcycle is included in the recall and you have paid forthe repair or replacement of the ignition switch you may befeligible for full or partial reimbursement Please note the following for which Suzuki may_ exclude reimbursement e Only repais that are the subject of the safety recall are reimbursable Additional expenses such as towtng rental accommodations damage repairs etc will not be reimbursed e Reimbursement may be limitedoto suggested list price on parts and the Suzuki published flat rate time allowance e An owner will not be eligible for reimbursement if the expenses for repairs are incurred more than 10 days after the date of the last owner notification
15. zuki s apologies for any inconvenience this recall campaign may cause them AFFECTED DEPARTMENTS The following departments in your dealership should be notified of this information x Management XI Service x Warranty X Sales I Parts X Accessories American Suzuki Motor Corporation Technical Service Department Motorcycle ATV 10 12 CUSTOMER NOTIFICATION LETTER Page One of Two SUZUKI June 10 2008 AMERICAN SUZUKI MOTOR CORPORATION MOTORCYCLE SAFETY RECALL CAMPAIGN 2A05 CERTAIN 2008 GSX1300RK8 HAYABUSA MOTORCYCLES IGNITION SWITCH INSPECTION REPLACEMENT Dear Suzuki Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act What is the reason for this notice Suzuki Motor Corporation has decided that_ajdefect which relates to motor vehicle safety exists in certain 2008 model year GSX1300RK8 motoreycles Suzuki Motor Corporation is conducting a voluntary Safety Recall Campaign According to our records you are the owner of one of these motorcycles What is the problem Suzuki Motor Corporation Aas determined that certam GSXTSOORK8 motorcycles may have the ignition switch lead wire improperly routed Handi barmovement can result in abnormal flexing and damage to the ignition switch lead wire Bamage to the ignition switch lead wire can result in intermittenieOr Complete loss of electrical power which can result in loss of lighting and or
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