GS/GSX/GSX-R#110: GSX1300RX Cam Chain Tension Adjuster RECALL
Contents
1. 16 Place the prop stand back in place on the inner rear fender Figure 14 17 Reinstall the rider and passenger seats D Mark by Engine Number 18 Use a fine line permanent black magic marker such as a SANFORD Sharpie permanent marker to draw an T before the engine number on the rear of the crankcase This will enable you to quickly identify a GSX1300R with a revised cam chain tension adjuster already installed figure 14 Draw a T in front of the engine number RIDE THE MOTORCYCLE To ensure customer satisfaction Suzuki suggests you ride the motorcycle several miles to make sure there are no abnormal engine sounds and the motorcycle operates correctly Clean any dirt or grime from the motorcycle before and after the test ride Correct any recall service related problems before delivering the motorcycle to the customer RECALL WARRANTY PARTS RETENTION Completely fill out and affix a warranty parts tag PN 99923 09822 003 to the replaced parts following recall service Hold these parts in your warranty parts retention area for inspection by your Technical Service Manager WARRANTY REIMBURSEMENT Warranty parts reimbursement rate of 100 will apply Labor will be reimbursed at 100 of your approved labor rate The total reimbursement time for this repair is 0 8 hour The flat rate time for the actual repair is 0 6 hour with an additional 0 2 hour allotted for warranty administration time Two types of SCAT rec2. SUZUKI Service Bulletin MOTORCYCLE DIVISION 4 STROKE BULLETIN NO GS GSX GSX R 110 DATE 10 13 1999 SAFETY RECALL CAMPAIGN GSX1300RX Hayabusa CAM CHAIN TENSION ADJUSTER MODEL 1999 GSX1300RX Hayabusa SUBJECT RECALL CAMPAIGN CAM CHAIN TENSION ADJUSTER REFERENCE GSX1300R SERVICE MANUAL PN 99500 39180 03E amp SERVICE BULLETIN GS GSX GSX R 108 FUEL HOSE ROUTING ATTACHMENT DEALER AND CUSTOMER LETTERS NOTICE Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists in all 1999 GSX1300RX Hayabusa model motorcycles Suzuki Motor Corporation is conducting a recall campaign for these motorcycles STOP DELIVERY OF GSX71300RX MOTORCYCLES IMMEDIATELY Effective immediately DO NOT DELIVER a GSX71300RX Hayabusa motorcycle to a customer until you complete the recall service described in this service bulletin Suzuki Motor Corporation has determined that the spring in the cam chain tension adjuster can break If this happens excessive slack will develop in the cam chain which can allow the cam chain to jump to the wrong position on the camshaft sprockets If the chain jumps to the wrong position severe engine damage can occur This may cause sudden engine failure Sudden engine failure while riding could cause rear wheel lockup disturbing the rider s ability to control the motorcycle and could cause a crash without prior warning Suzuki has developed a revised cam chain tension adjust
3. 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 Please telephone all of these customers and inform them of the need to have the recall service performed Suzuki will mail you a listing of affected motorcycles your dealership has sold and registered up to October 1 1999 Use this list to track the recall services you perform and to contact customers whose GSX1300RX motorcycles may not be registered and who you must contact and inform of the need to have the recall service performed UNITS OUT OF REACH If you are aware of any GSX1300RX motorcycles which have been scrapped stolen or exported outside of the United States send this information to the Suzuki Warranty Dept in Brea CA pew 9 12 Continued gt REPAIR PROCEDURES Service bulletin GS GSX GSX R 1 10 will contain instructions on how to perform the recall service You will replace the original cam chain tension adjuster with a revised cam chain tension adjuster and new tension adjuster gasket AUTOMATIC PARTS SHIPMENT FOR THIS CAMPAIGN RECALL SERVICE PARTS WILL BE AUTOMATICALLY SHIPPED TO YOUR DEALERSHIP Suzuki will send a tension adjuster recall kit for each GSX1300RX to the selling dealer of record Dealers will also receive a tension adjuster recall kit for each unsold GSX1300RX in their invent
4. the recall parts coordinator is the ONLY way to order GSX1300RX cam chain tension adjuster recall service parts Description Part Number Dir Price GSX1300RX 99103 11147 30 00 Tension Adjuster Recall Kit Each kit includes 1 Cam Chain 1 Cam Chain Tension Adjuster Tension Adjuster Gasket 12830 24F02 12837 24A10 REPAIR PROCEDURES You will install a revised cam chain tension adjuster and new tension adjuster gasket You will inspect and may replace other engine components which may have been damaged because of cam chain tension adjuster failure This recall service will be done at no cost to the customer for parts and labor See pages 3 through 6 for recall service instructions WARRANTY CLAIM PROCESSING The SCAT system will accept recall service warranty claims Dealers not using SCAT will need to complete and mail in a regular paper warranty request form for each recall service performed See pages 6 and 7 of this bulletin for warranty request information 2 12 Continued gt CAM CHAIN TENSION ADJUSTER REPLACEMENT PROCEDURE Refer to section 3 of the GSX1300R service manual for additional information on the recall service described in this bulletin 1 Place the motorcycle on a suitable service stand or on the centerstand if equipped 2 Remove the allen bolts securing the rider s seat and remove the seat from the motorcycle figure 1 3 Use the ignition key to unlock and remove the passenger se
5. F GSX7300RX MOTORCYCLES IMMEDIATELY Suzuki Motor Corporation has determined that the spring in the cam chain tension adjuster can break If this happens excessive slack will develop in the cam chain which can allow the cam chain to jump to the wrong position on the camshaft sprockets If the chain jumps to the wrong position severe engine damage can occur This may cause sudden engine failure Sudden engine failure while riding could cause rear wheel lockup disturbing the rider s ability to control the motorcycle and could cause a crash without prior warning Suzuki has developed arevised cam chain tension adjuster to replace the original cam chain tension adjuster Due to the serious nature of this situation Suzuki requires that you PERFORM THE RECALL SERVICE AS QUICKLY AS POSSIBLE ON YOUR CUSTOMERS MOTORCYCLES Join with us in promoting the safe use of Suzuki products AFFECTED UNITS All 1999 GSX1300RX Hayabusa model motorcycles are affected CUSTOMER NOTIFICATION For motorcycles that have already been delivered to customers perform the recall service as promptly as possible Attached is a letter being sent to all owners of affected motorcycles about whom we have information This letter will be mailed October 13 1999 If your dealership has sold a GSX1300RX to a customer but not yet mailed us the Sales In Service Registration card or submitted a SCAT entry send the sales information to American Suzuki AT ONCE We will send the
6. all warranty claim entry are available The Short Form claim entry requires just a few fields of information and can only be used in cases where the recall service parts kit are the only parts used for the repair The Short Form claim should be used for the majority of your recall warranty claims NOTE All recall service expenses for each motorcycle must be entered using a single warranty claim 6 12 Continued gt SCAT SHORT FORM RECALL SERVICE WARRANTY CLAIM INFORMATION 8 9 Select lt 3 gt SERVICE MENU Select lt 1 gt WARRANTY CLAIM ENTRY Enter the claim number xxxxx x Enter the claim type lt 31 gt SHORT FORM Enter the product type lt 2 gt MOTORCYCLE Enter your dealer number xxxxxx Select an entry type M Model Frame C Control Sequence Number V VIN Number Based on the Entry Type enter the identifying numbers Enter the repair date mm dd yy Enter the mileage no tenths 10 Enter the Campaign number 2039 SCAT LONG FORM RECALL SERVICE WARRANTY CLAIM INFORMATION To submit a SCAT Long Form recall service warranty claim or a regular paper warranty request use the information below You should only use the Long Form claim entry in situations where additional parts or labor such as valve timing inspection and correction were required to complete the recall service If submitting a paper claim have the customer sign the request before you mail it to the American Suzuki Warran
7. at or tail cover figure 2 4 Remove the allen bolts that secure the front fuel tank tabs to the frame figure 3 5 Remove the fuel tank prop stand from its clips on the inside of the rear fender figure 4 6 Insert the stepped end of the prop stand in the steering stem and the other end of the stand in the fuel tank mounting tab This will prop the fuel tank up to permit access to the top of the engine figure 5 3 12 Figure 1 Remove these bolts lift from front of seat Figure 2 Lift seat from rear Remove mounting bolts Figure We Gia l Prop st nd Figure 5 Continued gt 7 The cam chain tension adjuster is located on the right hand back edge of the cylinder head figure 6 While it is not required you can elect to remove the air cleaner assembly to enhance accessibility to the tension adjuster 8 Remove the two allen mounting bolts that hold the tension adjuster to the cylinder head figure 6 Remove the tension adjuster A CAUTION Do not use the electric starter to turn over the engine with the cam chain tension adjuster removed This can make the cam chain skip and change the valve timing damaging the engine 9 Clean any gasket remains off the adjuster mounting surface on the cylinder head A CAUTION Do not allow any portions of the tension adjuster gasket to fall into the engine This debris could block oil passageways and damage engine compo
8. d in the Push rod compressed position by the locking tool figure 3 Tension If the locking tool is missing or the push rod adjuster is extended reset the tension adjuster push rod to the compressed position Follow the instructions in section 3 of the GSX1300R service manual Locking tool wre Tension adjuster locking tool PN 09917 62430 12 Install the revised cam chain tension N Mounting adjuster with the included new gasket into polg cylinder head figure 10 Tighten the tension adjuster mounting bolts to the specified torque Tension adjuster mounting bolt torque Gasket 10Nm 1 0kgf m 7 0 lb ft Figure 11 13 Release the cam chain tension adjuster push rod by removing the locking tool figure 11 Locking A click sound will be heard from the tension adjuster as the push rod is released Figure 12 14 Install the supplied cam chain tension adjuster bolt and gasket into the end of the tension adjuster figure 12 Tighten the tension adjuster bolt to the specified torque 8 Tension adjuster bolt Tension adjuster bolt torque Basket 8 Nm 0 8kgf m 6 0 lb ft 5 12 Continued gt Figure 13 Route fuel hoses per Service Bulletin GS GSX GSX R 7108 WS Before removing the prop stand and lowering the fuel tank in place refer to Service Bulletin GS GSX GSX R 108 to make sure the fuel hose routing is correct figure 13 15 Reinstall the fuel tank mounting bolts
9. er to replace the original cam chain tension adjuster Due to the serious nature of this situation Suzuki requires that you PERFORM THE RECALL SERVICE AS QUICKLY AS POSSIBLE ON YOUR CUSTOMERS MOTORCYCLES Join with us in promoting the safe use of Suzuki products AFFECTED UNITS All 1999 GSX1300RX Hayabusa model motorcycles are affected CUSTOMER NOTIFICATION For motorcycles that have already been delivered to customers perform the recall service as promptly as possible Attached to this bulletin a copy of the letter sent to all owners of affected motorcycles about whom we have information This letter was mailed on October 13 1999 1 12 Continued gt gt CUSTOMER NOTIFICATION continued If your dealership has sold a GSX1300RX to a customer but not yet mailed Suzuki the Sales In Service Registration card or submitted a SCAT 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 customers with unregistered motorcycles you must immediately notify these customers of the recall campaign Please telephone all of these customers and inform them of the need to have the recall service performed Suzuki will mail you a listing of affected motorcycles your dealership has sold and registered up to October 1 1999 Use this list to track the recall services you
10. ership personnel are familiar with the recall service procedures 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 Suzuki s apologies for the inconvenience this recall service may cause them Thank you for your cooperation in conducting this very important campaign for your customers safety AFFECTED DEPARTMENTS The following departments in your dealership should be notified of this information Kl Management X Service K Warranty K Sales X Parts X Accessories American Suzuki Motor Corporation Technical Service Department Motorcycle Continued gt 8 12 SUZUKI October 6 1999 AMERICAN SUZUKI MOTOR CORPORATION MOTORCYCLE SAFETY RECALL CAMPAIGN GSX1300RX Hayabusa CAM CHAIN TENSION ADJUSTER Dear Suzuki Dealer This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Suzuki Motor Corporation has decided that a defect which relates to motor vehicle safety exists in all 1999 GSX1300RX Hayabusa model motorcycles Suzuki Motor Corporation is conducting a recall campaign for these motorcycles Effective immediately DO NOT DELIVER a GSX1300RX to a customer until you complete the recall service described in service bulletin GS GSX GSX R 110 which will be sent to your dealership STOP DELIVERY O
11. i Motor Corporation has decided that a defect which relates to motor vehicle safety exists in all 1999 GSX1300RX Hayabusa model motorcycles Suzuki Motor Corporation is conducting a recall campaign for these motorcycles According to our records you are the owner of one of these motorcycles Suzuki Motor Corporation has determined that the spring in the cam chain tension adjuster can break If this happens excessive slack will develop in the cam chain which can allow the cam chain to jump to the wrong position on the camshaft sprockets If the chain jumps to the wrong position severe engine damage can occur This may cause sudden engine failure Sudden engine failure while riding could cause rear wheel lockup disturbing the rider s ability to control the motorcycle and could cause a crash without prior warning A WARNING DO NOT RIDE YOUR GSX1300RX Hayabusa UNTIL THE CAM CHAIN TENSION ADJUSTER RECALL SERVICE IS COMPLETED Suzuki strongly suggests you do not ride your GSX1300RX Hayabusa until the cam chain tensioner recall service is completed If you elect to ride your motorcycle to the dealership operate the engine in a gentle low RPM manner Avoid sudden acceleration or deceleration Be prepared to pull in the clutch lever in case of engine failure or rear wheel lock up If you are concerned about your safety or the safety of your vehicle trailer or truck your motorcycle to your dealer for your scheduled recall service Contact the service
12. ime It is your responsibility to perform the recall service on any affected motorcycle brought to your dealership even if your dealership did not originally sell the motorcycle Allrecall campaign service is to be done at no cost to the customer for parts and labor Incidental costs your customers may incur are not normally covered However if you have a customer with special needs such as motorcycle transportation contact your Technical Service Manager to discuss possible solutions CUSTOMER SATISFACTION Please be sure that all dealership personnel are familiar with the recall service procedures 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 Suzuki s apologies for any inconvenience this recall service may cause them We 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 Sincerely American Suzuki Motor Corporation 10 12 Continued gt SUZUKI AMERICAN SUZUKI MOTOR CORPORATION MOTORCYCLE October 13 1999 SAFETY RECALL CAMPAIGN GSX1300RX Hayabusa CAM CHAIN TENSION ADJUSTER Dear Suzuki Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Suzuk
13. manager or the owner of your Suzuki dealer if you require assistance in transporting your motorcycle to the dealership for the recall service WHAT WILL BE REPAIRED ON YOUR MOTORCYCLE Your authorized Suzuki motorcycle dealer will replace the original cam chain tension adjuster with a revised cam chain tension adjuster This recall service will be done at no cost to you for parts and labor PARTS AVAILABILITY Suzuki is sending recall service parts to the dealer from which you purchased your GSX1300RX Hayabusa Tension adjuster recall service parts for all GSX1300RX motorcycles are being shipped now so there will be minimal delay in having your motorcycle serviced Suzuki anticipates all recall service parts will be delivered to dealerships during the week of October 11 1999 If you cannot contact the dealer who sold you your GSX1300RX Hayabusa call toll free 1 800 255 2550 for your nearest Suzuki dealer TO RECEIVE THE FASTEST POSSIBLE SERVICE Suzuki understands that your riding time is precious Our suggestion is to work closely with your authorized Suzuki dealer to get your motorcycle s recall service scheduled and performed as quickly as possible 11 12 Continued TO RECEIVE THE FASTEST POSSIBLE SERVICE continued Schedule an appointment for the recall service to be performed By scheduling a precise time that you can visit the dealership your dealer will be prepared to perform the recall service once your motorcycle is i
14. n the service department While the actual recall service takes approximately one hour you may need to leave your motorcycle overnight to have the recall service completed If additional repairs or parts are required your dealer will advise you on how much longer your motorcycle will be in for repair When you pick up your repaired motorcycle please allow a few additional minutes for your dealer to prepare and complete the necessary warranty claim paperwork with you Bring your motorcycle to your Suzuki dealer If you decide to transport your motorcycle rather than ride it take care securing and protecting your motorcycle for transportation If you have special circumstances discuss them with your Suzuki dealer Suzuki understands that some customers may have unique or very 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 However please remember 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
15. nents 10 The revised style tension adjuster can be identified by appearance of the push rod guide and three pink paint dots figure 7 If the push rod does not fully extend when the tension adjuster is removed from the engine the internal spring may be broken A broken tension adjuster internal spring or customer complaint about abnormal valve train sounds or poor engine performance could indicate the valve timing has been disrupted If you suspect the valve timing is disrupted remove the RH fairing to access the timing window on the motor cover Remove the valve cover to check and reset the valve timing per section 3 of the service manual figure 8 After resetting the valve timing measure and record the engine s compression Compare the reading with the specifications listed in section 8 of the service manual Low compression may indicate valve train damage If you suspect valve train damage contact TECH LINE or your TSM for authorization to proceed with further inspection and repair 4 12 Figure 6 View from above cylinder head Tension adjuster Figure 7 Press metal Two pink light gray color paint dots ORIGINAL STYLE Push rod Push guide rod Three pink paint dots Sintered metal dark gray color Figure 8 Timing window on RH engine cover Continued gt 11 Make sure the push rod of the revised R Figure 9 cam chain adjuster is being hel
16. ng pleasure are priorities for Suzuki Sincerely American Suzuki Motor Corporation 12 12 END
17. ory You can NOT use your normal parts ordering procedure to order these recall service parts Recall service parts shipping from Suzuki s Brea CA warehouse will begin on October 6 1999 Suzuki anticipates all recall service parts will be delivered to dealerships during the week of October 11 1999 Parts will be shipped freight pre paid UPS 3 day delivery The recall service parts will be billed to your parts account at 90 day net terms ORDERING ADDITIONAL RECALL SERVICE KITS If you need a recall service kit for a GSX1300RX motorcycle your dealership did not sell contact the recall parts coordinator at 714 996 7040 extension 551 Be prepared with your dealer number and telephone number your customer s name and vehicle VIN information when you place your call Calling the recall parts coordinator is the ONLY way to order GSX1300RX cam chain tension adjuster recall service parts Description Part Number Dir Price GSX1300RX 99103 11147 30 00 Tension Adjuster Recall Kit WARRANTY CLAIM PROCESSING Service bulletin GS GSX GSX R 110 will contain information on how to submit your recall service warranty claim s IMPORTANT Successful completion of this recall campaign depends on your efforts It is very important that your dealership contact each customer and inform them of the need to have this recall service performed You must perform the recall service and submit a SCAT claim or Warranty Request Form within the shortest possible t
18. perform and to contact customers whose GSX1300RX motorcycles may not be registered and who you must contact and inform of the need to have the recall service performed UNITS OUT OF REACH If you are aware of any GSX1300RX motorcycles which have been scrapped stolen or exported outside of the United States send this information to the Suzuki Warranty Dept in Brea CA AUTOMATIC PARTS SHIPMENT FOR THIS CAMPAIGN RECALL SERVICE PARTS WILL BE AUTOMATICALLY SHIPPED TO YOUR DEALERSHIP Suzuki will send a tension adjuster recall kit for each GSX1300RX to the selling dealer of record Dealers will also receive a tension adjuster recall kit for each unsold GSX1300RX in their inventory You can NOT use your normal parts ordering procedure to order these recall service parts Recall service parts shipping from Suzuki s Brea CA warehouse began on October 6 1999 Suzuki anticipates all recall service parts will be delivered to dealerships during the week of October 11 1999 Parts will be shipped freight pre paid UPS 3 day delivery The recall service parts will be billed to your parts account at 90 day net terms ORDERING ADDITIONAL RECALL SERVICE KITS If you need a recall service kit for a GSX1300RX motorcycle your dealership did not sell contact the recall parts coordinator at 714 996 7040 extension 551 Be prepared with your dealer number and telephone number your customer s name and vehicle VIN information when you place your call Calling
19. ty Dept in Brea CA USE 2039 FOR THE PAPER CLAIM NUMBER cross off the paper warranty request s original number FAILED PART NUMBER 99103 11147 QTY 1 TENSION ADJUSTER KIT OTHER PART S As needed QTY As needed COMPLAINT CODE 99 DEFECT CODE D2 LABOR OPERATION AH9999 LABOR TIME As necessary REPAIR INSTALL CAM CHAIN TENSION ADJUSTER PER RECALL SERVICE BULLETIN GSX R 110 REM EMBER Long form or paper warranty claims with parts or labor in addition to th e recall kit requires prior authorization PAS from TECH LINE or your TSM 7 12 Continued gt IMPORTANT Successful completion of this recall campaign depends on your efforts It is very important that your dealership contact each customer and inform them of the need to have this recall service performed You must perform the recall service and submit a SCAT claim or Warranty Request Form within the shortest possible time It is your responsibility to perform the recall service on any affected motorcycle brought to your dealership even if your dealership did not originally sell the motorcycle All recall campaign service is to be done at no cost to the customer for 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 to discuss possible solutions CUSTOMER SATISFACTION Please be sure that all deal
20. you the fastest response 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 any difficulty having the recall service performed to your motorcycle you may contact American Suzuki Customer Service Department for assistance at 714 996 7040 extension 396 If you believe that 1 Suzuki or your Suzuki dealer has failed to or is unable to perform the recall service without charge or 2 you believe Suzuki has failed to or is unable to perform the recall service to your vehicle within 60 days after you first brought your vehicle to your Suzuki dealer after October 25 1999 you may submit a complaint to the Administrator National Highway Traffic Safety Administration 400 Seventh Street S W Washington D C 20590 or call the toll free Auto Safety Hotline at 800 424 9393 Washington DC area residents may call 366 0123 If you no longer own a GSX1 300RX Hayabusa or never owned one please fill out and mail the enclosed postage paid pre addressed reply card If you sold your GSX1300RX Hayabusa please fill in the name and address of the person to whom you sold your motorcycle This will help us notify the new owner about this recall campaign We thank you for your prompt attention to completing this recall service on your Suzuki motorcycle We apologize for any inconvenience this recall campaign causes you Your safety satisfaction and ridi
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