VFR recall

On the ADVRiders web site there was a reference to a recall notice about eletrical problems in the '02-'05 VFR's

http://www.advrider.com/forums/showthread.php?t=265541

Anyone else get a notice?

I haven't as of yet for my new '05.

 

You probably won't get a notice for at least a month or so.



August 31, 2007

Dear Honda Motorcycle Dealer:

SAFETY RECALL NOTICE


AFFECTED UNITS: All 2002-2005 VFR800/VFR800A Motorcycles


American Honda is conducting a SAFETY RECALL on affected models per the description above. The recall will correct a defect that exists in the wiring harness of 2002-2005 model year VFR800 motorcycles. In limited circumstances, the ground wire terminals inside the connectors between the main wiring and fairing subharness can overheat, resulting in the melting of the connector and a loss of power to various circuits. As a result, a loss of critical lighting or engine power could occur without warning, which could result in a crash.

Effective immediately YOU MUST NOT SELL any affected model in either your new or used motorcycle inventory until the required repair has been completed. Please make sure ALL DEPARTMENTS in your dealership - Parts, Sales, and Service - are made aware of this action. Any sale of an affected motorcycle after receiving this notice and prior to the required repair is a violation of Federal law.

The instructions, procedures, and parts necessary to repair affected motorcycles will be made available to your dealership as soon as possible. Date-specific information as to each of these items will be sent to you the week of September 10, 2007.

American Honda will mail a notice of this Recall to owners of all affected motorcycles beginning September 10, 2007.

If you have recently sold an affected model, please submit the warranty registration information. If you have any further questions, please contact either American Honda’s Techline or your District Service Manager.


Thank you for your cooperation.
American Honda Motor Co., Inc.


Robert E. Clever
Senior Manager – Service
Motorcycle Division

 

I got my letter a few days ago.

 

Just got my letter yesterday, said a second letter was to follow when dealers have the parts to fix the problem.

 

OK time to tell my story as I had a trip ruined by this particular situation.

I left for day 1 of a 9 day tour through West Virginia, Virginia, North Carolina, Tennesse and Georgia on September 8th. This was to be my annual long tour that I've grown to love.

Roughly 7 hours into my journey on Route 9 in West Virginia, my bike suddenly shut off after taking a hard set of curves. WTF? I initially thought I may have bumped my kill switch? I reset it, start the bike and continue on my way only to have the bike shut down again within seconds. OK now I know I have a problem. I limp the stalling bike to the first gas station I came to. After removing my earplugs, I could clearly hear the buzzing sound that the recall notice describes. Sounded horrible! The relays were buzzing like mad! First thing I did was check my battery terminals to make sure they were tight, all checked out. Fuses...check! Nothing out of whack anywhere.

I was lucky enough to be directed to a Honda dealership a mere 3 miles away so I put the bike back together and headed there immediately. The one mechanic was correct in his initial diagnosis of a faulty ground wire. There were so many things acting weired that he thought for certain it was a ground wire, problem was we couldn't find it. After roughly 1.5 hours of searching for a ground wire problem we gave up and bolted the bike back together. The guy I was working with didn't mess with street bikes a lot according to him and I personally didn't know where to look. Plus it was late on a Saturday afternoon so their willingness to spend the time wasn't there. Recognizing I didn't have their full attention I rode home 250 miles on I-81 with a bike that would stall, had no headlights or turn signals. Fun stuff!

I take the bike to my friend who is an electrical guru. After acquiring a wiring diagram off the web, he traces the ground wires to the harness where we could see one of the wires had burned. The plugs were stuck together from the heat. He made a "jump" which basically connected both sides of the wire together bypassing the harness. The bike is perfectly fine now.

Boy was I pissed! Trip ruined and an issue totally un-Honda like in my opinion.

So what arrives today??? My letter about the recall....grrrrrr!!!!! At least I know I don't have a lemon or something...

 

I recently bought a lightly used (2500 miles) 2003 VFR in immaculate shape at the beginning of the month. First Honda product I have owned/ridden.

I have had a habit of using the high beams in daylight hours.

The bike was stored for a couple of years, it runs great, but I only have been riding it for a couple of days as I have been in Japan from September 5th until this past Thursday. Put about 200 miles on it this weekend in city, mountains, and interstate, no issues at all.

Any suggestions in the context of the recall (I imagine the letter will go to the original owner who I bought the bike from).

-Don't use the high beams?
-Check voltage at the batt?

Opinions welcome, thanks.
Anyone from the Salt Lake area with suggestions on a good dealer to check with?

 

just checking in

I got my letter this week, included was a customer service number,

1-866-784-1870

I called and was informed that I was not to ride till repairs could be made. A fix was in the works in Japan and the gentleman said perhaps November I could get notice of the parts being available.

Sure glad I still have my old CB 650 to ride!

Just 25 years young.

 

Just put a quick tap on the green wire on both sides of the blue connector, wire those quick taps to a ground.

 

Thanks for the tip, but would that create any problems about modifing the wire harness from stock or something?

 

No. It is a recall, not a warranty issue where they might try to blame you for something, they will do the fix no matter what.

This was actually the fix that Honda has been instructing dealers to do that encounter the blue connector issue for a few years now. This is the fix a dealer did in early 2004 for this problem:

 

That fix is basically the same thing I did to mine only I don't have a quick disconnect on it. I'll get to that next time.

 

That very problem is what brought my ride to Americade in N.Y. this summer to a screeching hault (hehe). I posted the problem back in june, had it repaired the following week, and just recieved my letter!
Everything the letter said might happen, did!

 

jeremy556 thanks for posting so much info the picture says it all. have not got a recall letter yet and probably wont bike is a US model doubtfull they will mail one to canada. did regester bike with honda us owners link and so far no recall for my vin#. im thinking i should do the fix my self any ways

because i didnt get a letter and from the picture you posted the problam looks like its with the blue connector over heating on the ground wire terminal (Green) and a simple bypass with the original wire is all thats needed? is this right?
thanks
Jeff

 

Here is a picture of my bike. I went a step further and connected both sides of the harness to a known ground point. Some people have had problems with the ground junction blocks inside the taped up part of the wire harness going bad, so I figured better to be safe than sorry,

 

Jeremy thank you for the picture it really helps. I know what to look for if I have a problem. I also had the 30 amp fuse problem off the battery, I fixed it last winter. Don Ripa

 

Nice pictures with clear information, thanks again. I just got a call from the previous owner on my bike, say he got the recall letter in the mail and will be forwarding it to me. Called my local dealerships, both were unaware of any recall. SO, looks like we all have to wait this out a little longer until they get the parts. My 04 vfr has 28,000 miles on it, i would think if it were going to have a problem it would have already. I'm still riding it dailly. But I'm going to pull the side panel and check everything this weekend.

 

My good friend has an '03 with 32,000 on it and he hasn't had the issue either. Mine only had 9200 or so when it happened. Difference between us two? I run my high beam all the time during the day and he doesn't. It's an easy band-aid should it occur to you. I wish I was aware of this issue before I left for my trip, would have saved me a ton of agravation. Oh well...

 

Guys, I built the ground too but should point out mine happened because of a meltdown in the central ground clip located in the mid section of the main harness, not the blue connector. This exact same thing happened to an 04 VFR about 6 months before mine. Below is a pic of the clip...

 

I have heard of a few people that has happened to, and the reason I recommend not only bypassing the blue connector, but to also add your own ground as well. I think there are 2 or 3 of those ground blocks, was yours the one wrapped in the harness under the tank?

 

Yes and FAR too close to the fuel lines. You know, I'm reading about thermal damage to the blue connector, the ECM, the 30 amp fuse off the battery, the ground clip, far too many problems directly traceable to substandard wiring. I can't help but think Honda, to save money, cut corners on the wiring specs, something that with the "fast" response is putting us at real risk. I am very seriously considering legal action...