IN THE TRANSMISSION ON CERTAIN MOTORCYCLES, THE SECOND/THIRD PINION GEAR MAY BE INCORRECTLY MACHINED

Aug 26, 2003 — Recall Campaign #03V309000

IN THE TRANSMISSION ON CERTAIN MOTORCYCLES, THE SECOND/THIRD PINION GEAR MAY BE INCORRECTLY MACHINED WHICH COULD CAUSE ABNORMAL WEAR THAT EVENTUALLY RESULTS IN A BROKEN RETAINER CIRCLIP.

The recall was influenced by the Office of Defects Investigation with about 29,139 units affected.

See recall notice

NHTSA Safety Recall Notice

03V309000

Manufacturer:	Yamaha Motor Corporation, USA
Recall date:	August 26, 2003
NHTSA Campaign #:	03V309000
Units affected:	29,139

Description:: IN THE TRANSMISSION ON CERTAIN MOTORCYCLES, THE SECOND/THIRD PINION GEAR MAY BE INCORRECTLY MACHINED WHICH COULD CAUSE ABNORMAL WEAR THAT EVENTUALLY RESULTS IN A BROKEN RETAINER CIRCLIP.
Consequeces:: IF THE CIRCLIP BREAKS, THE TRANSMISSION COULD LOCK UP, WHICH WOULD ALSO CAUSE THE REAR WHEEL TO LOCK UP. THIS COULD RESULT IN LOSS OF CONTROL AND A CRASH, POSSIBLY RESULTING IN SERIOUS INJURY OR DEATH.
Corrective action:: YAMAHA WILL REPLACE THE TRANSMISSION GEARS AND SHAFTS WITH NEW ONES. OWNER NOTIFICATION BEGAN ON SEPTEMBER 9, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT YAMAHA AT 1-800-88-YAMAHA OR VISIT THEIR WEBSITE AT WWW.YAMAHA-MOTOR.COM.
Notes:: ALSO, CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Affects the following:

2001 YAMAHA XV1600AN Complaints
CONSUMER RECEIVED NHTSA RECALL 03V309000 CONCERNING TRANSMISSION FAILURE. CONSUMER CONTACTED YAMAHA TO FIND OUT WHEN THE PARTS WERE GOING TO BE SENT TO THE DEALERS. MANUFACTURER INFORMED THE CUSTOMER THAT PARTS WOULD BE AVAILABLE THE FIRST OF MARCH 2004. HOWEVER, PARTS WERE NOT AVAILABLE. CONSUMER CONTACTED THE MANUFACTURER AGAIN, BUT MANUFACTURER HAD NO INFORMATION ON WHEN THE PARTS WILL BE AVAILABLE.*AK *MR;
2001 YAMAHA XV1600ASNC Complaints
DT*: THE CONTACT STATED WHILE DRIVING AT 40 MPH., THERE WAS AN ABNORMAL NOISE HEARD COMING FROM THE ENGINE. THE VEHICLE WAS DRIVEN HOME. THE MANUFACTURER WAS CONTACTED ABOUT RECALL INFORMATION HOWEVER, NO RECALL INFORMATION WAS ON RECORD FOR THE VIN NUMBER GIVEN. THE ENGINE AND TRANSMISSION WAS INSPECTED BY THE CONTACT WHO DISCOVERED THE 4TH GEAR PINION CLIP AND TEETH WERE FRACTURED. THE MODEL OF THE MOTORCYCLE WAS MODEL # XV16ATNB.;
2001 YAMAHA XV1600ASNC Complaints
DT*: THE CONTACT STATED WHILE DRIVING AT 40 MPH., THERE WAS AN ABNORMAL NOISE HEARD COMING FROM THE ENGINE. THE VEHICLE WAS DRIVEN HOME. THE MANUFACTURER WAS CONTACTED ABOUT RECALL INFORMATION HOWEVER, NO RECALL INFORMATION WAS ON RECORD FOR THE VIN NUMBER GIVEN. THE ENGINE AND TRANSMISSION WAS INSPECTED BY THE CONTACT WHO DISCOVERED THE 4TH GEAR PINION CLIP AND TEETH WERE FRACTURED. THE MODEL OF THE MOTORCYCLE WAS MODEL # XV16ATNB.;
2003 YAMAHA MIDNIGHT STAR Complaints
I AM WRITING IN REGARD TO THE TRANSMISSION FAILURE THAT I EXPERIENCED ON SATURDAY, THE 25TH OF AUGUST, 2007 ON MY 2003 MIDNIGHT ROADSTAR. FIFTH GEAR WAS LOST WHILE I WAS LEADING A GROUP OF MOTORCYCLES ON THE INTERSTATE. AT THE TIME OF THE FAILURE, I HEARD A LOUD METALLIC CLICK, AND THOUGHT OF A BREAKAGE OF THE CIRCLIP. THIS FAILURE HAD THE POTENTIAL TO RESULT IN THE IMMEDIATE LOCKUP OF THE TRANSMISSION, AND RESULTANT LOCKUP OF THE REAR WHEEL. THIS EVENT COULD HAVE LED TO A CATASTROPHIC CRASH BECAUSE IT OCCURRED AT HIGHWAY SPEEDS WITH A GROUP OF MOTORCYCLES IMMEDIATELY BEHIND ME. IN FIFTH GEAR, NO POWER AT ALL IS PROVIDED TO THE DRIVE BELT. GEARS 1-4 AND NEUTRAL CONTINUED TO OPERATE NORMALLY DURING THIS PERIOD. A LOCAL YAMAHA DEALER (CYCLE SPORT OF ALEXANDRIA, VA) HAS WORKED ON THE TRANSMISSION ON TWO PREVIOUS OCCASIONS; ONCE TO REPLACE THE CLUTCH IN NOVEMBER 2003, AND ONCE TO ACCOMPLISH THE TRANSMISSION RECALL INVOLVING THE REPLACEMENT OF A CIRCLIP THAT, UPON FAILURE, COULD RESULT IN IMMEDIATE LOCKUP OF THE TRANSMISSION, LEADING TO POTENTIAL IMMEDIATE LOCKUP OF THE REAR WHEEL. I HAVE FOLLOWED THE DEALERS RECOMMENDATION REGARDING THE ENGINE OIL (WHICH IS SHARED BY THE TRANSMISSION) SINCE DELIVERY OF THE VEHICLE WHEN IT WAS NEW. MY BELIEF IS THAT IT IS REASONABLE TO EXPECT RELIABLE TRANSMISSION SERVICE BEYOND 28,000 MILES. MY CONCERNS INCLUDE THE POSSIBILITY THAT THE RECALL WAS NOT PERFORMED PROPERLY, OR AT ALL, OR THAT THE DEALER?S RECOMMENDATION FOR THE OIL USED IN THE BIKE MAY HAVE BEEN ERRONEOUS. I HAVE COMMUNICATED THIS INFORMATION TO YAMAHA CUSTOMER SERVICE AND HAVE NOT YET RECEIVED A RESPONSE. MY CONCERN IS THAT THIS FAILURE COULD ALSO HAPPEN TO OTHERS, WITH POTENTIALLY CATASTROPHIC RESULTS. *TR UPDATED 03/13/08. *LJ;