old product update campaign: 2002 VFR800 AC Generator

In October 2002 Honda issued a "product update campaign" for the 2002 VFR800's AC Generator (aka alternator, stator). There's scattered information on line, but I thought I'd compile it into one thread for fellow 2002 owners. Please point out and forgive any mistakes.

In summary, the 2002 has an undersized alternator that does not charge the battery sufficiently under certain conditions. The campaign replaces the 2002 stator and flywheel with those from the 2003+ models. The campaign has ended, so if the upgrade has not been done on a 2002 then Honda will not cover it. But the information is still important for when it's time to replace a stator on a 2002.

The service bulletin and letter to owners is at VFRD here:
https://www.google.com/url?sa=t&rct...freeA1wYwVM5Fhzbg&sig2=p0G2NOLUI8FltLM-CUQczw

AFFECTED UNITS
All 2002 VFR800/A models

October 2002
Dear 2002 VFR800/A Owner:
RE: Product Update Campaign
American Honda's Motorcycle Division is conducting a Product Update Campaign to replace 2002 VFR800/A alternator assemblies that may produce inadequate output during certain riding conditions. Our records indicate that you own one of these motorcycles.

Frequent battery discharge or the starter’s inability to crank the engine may occur if the high beam and radiator fan are both in operation when riding at low engine speeds or idling for an extended period of time. To improve charging system performance under these conditions, a new, higher output alternator is now available.

Please contact your nearest authorized Honda motorcycle dealer and make an appointment to have the alternator assembly inspected and replaced. The dealer will replace the parts at no cost to you. Please plan to leave your motorcycle at the dealer for at least half a day to allow for dealer scheduling.

This Product Update Campaign ends October 17, 2007. You must have your VFR800/A updated prior to this date; after this date your motorcycle will no longer be eligible to have this update performed free of charge.

As this update also applies to subsequent owners, please keep this letter with the Owner’s Manual. If you have moved or no longer own your 2002 VFR800/A, please take a moment to complete and mail the enclosed Information Change Card so we can update our records.

You may visit our website at www.hondamotorcycles.com and click on “locate a dealer” to find a dealer who can assist you. Should you need assistance locating a dealer or have questions about this campaign, please call Motorcycle Customer Support at (310) 532-9811.

If you have previously paid for the replacement of the alternator assembly or battery, contact your Honda dealer for reimbursement information.

We apologize for any inconvenience this may cause you.

Thank you for your VFR800/A purchase.

Sincerely,
American Honda Motor Co., Inc.
Motorcycle Division

On my 2002 VFR800 a previous owner did not have the stator/flywheel upgraded. The charging system is in good shape: fairly new Yuasa battery, clean/Oxgarded connectors, OEM stator and R/R (with 20k mi). It delivers a steady 14.2V at the battery terminals at idle and 5000rpm with the low beams on. But with the high beams on, voltage at idle drops to an alarming 12.9V and rises back to 14.2V at 5000rpm. So, with the high beams on at idle, the battery is roughly breaking even. But if the cooling fan turns on or power-hungry accessories are running, the charging system won't be able to keep up with demand and the battery will drain.

To solve this, Honda upgraded the stator/flywheel for 2003+ and issued the product update campaign for 2002 models to upgrade those parts to the 2003+ version (both stator and flywheel must be upgraded). The campaign ended in 2007 so if it hasn't been done, Honda will not cover the cost.

The 2002 VFR800 stator (31120-MCW-D01) and flywheel (31110-MCW-D01) have been discontinued. Instead, there is a replacement kit available (31100-MCW-305) containing all the new parts needed for the update: flywheel, stator, cover gasket, and 4 bolts (stator-to-cover, they cannot be reused from the 2002). The MSRP for the kit is $381, but PartZilla has it for $251. While this is more expensive than a new stator alone (MSRP $297, PartZilla $178), it's cheaper than buying each part separately (MSRP for that would be about $581).

If this update has not been done, it's not necessarily critical to have it done ASAP. Most riders will not notice the underperformance of the charging system at idle unless they are running many accessories (or, I guess, riding in stop and go with high beams on). For most owners it probably makes sense to wait to do the upgrade when the motorcycle needs a new stator.

For someone considering buying a 2002, this charging issue shouldn't necessarily dissuade them. To my knowledge, stator life on a 2002 is no different than on the 2003+. When the stator/flywheel need to be replaced, it's in practice only about $70 more expensive than the comparable job (replacing the stator alone) on a 2003+ assuming you do the work yourself. Even if a shop does the work, the marginal cost of replacing the flywheel shouldn't be more than ~$30.

Installation is very well-explained here:
http://www.vfrdiscussion.com/forum/...replace-stator-and-flywheel-how-to-with-pics/

 

Ok...so before I picked up my 2002..the owner took it to a honda dealer for the recall...is it safe to say thats whats been done?

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The front harness replacement was the recall. This is technically a "product update campaign" which some people might call a recall (though they are different). The product update campaign ended in 2007, so if the previous owner did it after that it was probably the harness recall.

 

Thanks for posting this, good info for us '02 owners. Thankfully I've had no electrical issues so far but this has dissuaded me even more from pursuing any electrical mods.

 

It shouldn't dissuade you completely from electrical mods. Unless you're doing excessive stop 'n go, the battery should be reasonably well fed. If you do add electrical accessories, you just have to consider how much wattage they draw and might want to consider installing a voltmeter. Or you could upgrade to the 2003+ stator/flywheel.

 

Ok so just replaced my battery after 4 1/2 years... Have a cigarette lighter plug which I never use and HID low beams. I do ride my bike in the day with my brights on but rarely stop and go traffic... its all highway miles. Guess I should do a voltage test. Never had one problem with my 2002 but would hate to get stranded.

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Who wants to trade fly wheels with me? I want a light weight race fly wheel!


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