ON CERTAIN MOTORCYCLES, THE MAIN WIRE HARNESS HAS A GROUND DISTRIBUTION CONNECTOR THAT IS INCORRECTLY

Dec 09, 2004 — Recall Campaign #04V568000

ON CERTAIN MOTORCYCLES, THE MAIN WIRE HARNESS HAS A GROUND DISTRIBUTION CONNECTOR THAT IS INCORRECTLY ASSEMBLED. SOME ELECTRICAL CIRCUITS MAY OVERHEAT AND SHORT, INCLUDING THE FUEL PUMP.

The recall was influenced by the manufacturer with about 4,345 units affected.

See recall notice

NHTSA Safety Recall Notice

04V568000

Manufacturer:	Honda (American Honda Motor Co.)
Recall date:	December 09, 2004
NHTSA Campaign #:	04V568000
Units affected:	4,345

Description:: ON CERTAIN MOTORCYCLES, THE MAIN WIRE HARNESS HAS A GROUND DISTRIBUTION CONNECTOR THAT IS INCORRECTLY ASSEMBLED. SOME ELECTRICAL CIRCUITS MAY OVERHEAT AND SHORT, INCLUDING THE FUEL PUMP.
Consequeces:: IF THE FUEL PUMP STOPS WORKING, THE ENGINE WILL STALL WITHOUT WARNING, WHICH COULD CAUSE A CRASH.
Corrective action:: DEALERS WILL INSPECT THE GROUND DISTRIBUTION CONNECTOR FOR OVERHEATING DAMAGE. IF ANY DAMAGE IS FOUND, THE WIRE HARNESS WILL BE REPLACED. IF NO DAMAGE IS FOUND, THE CONNECTORS WILL BE ASSEMBLED PROPERLY. THE RECALL BEGAN ON DECEMBER 8, 2004. OWNERS SHOULD CONTACT HONDA AT 866-784-1870.
Notes:: CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Affects the following:

2004 HONDA ST1300 Complaints
TL* THE CONTACT OWNS A 2004 HONDA ST1300 MOTORCYCLE. WHILE INSPECTING THE VEHICLE, THE FLUID LEVELS IN THE BRAKE FLUID RESERVOIR WERE LOW. THERE WAS NO EVIDENCE OF A FLUID LEAK. WHILE RIDING APPROXIMATELY 45 MPH, THE CONTACT HEARD A LOUD POPPING NOISE FROM THE REAR OF THE BIKE AND THE REAR BRAKES SUDDENLY BECAME INOPERABLE. UPON INSPECTION, THE CONTACT DISCOVERED THAT THERE WAS NO BRAKE FLUID PRESENT IN THE BRAKE RESERVOIR. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 18,000.;
2004 HONDA ST1300A Complaints
MOTORCYCLE DEMONSTRATED ONCE BEFORE THE BOILING OF FUEL IN FULL FUEL TANK AFTER DRIVING. A COUPLE OF WEEKENDS LATER I DECIDED THAT I WOULD REMOVE THE FUEL FROM THE TANK BECAUSE I BELIEVED THAT THE GAS MAY HAVE CONTAINED TOO MUCH ALCOHOL WHICH MAY BOIL AT A LOWER TEMPERATURE. I REMOVED ALL BUT ABOUT 2 GALLONS OUT OF THE 7.7 GALLON TANK. I RODE TO A FUEL STATION AND REFILLED TO ABOUT 3/4 OF AN INCH BELOW THE FULL MARK. I LEFT SOME EXPANSION SPACE DUE TO THE HOT WEATHER. THE OPERATING TEMPERATURE OF THE BIKE WAS NORMAL AS ALWAYS. UPON RETURNING HOME I STOPPED THE BIKE OUTSIDE OF THE ENCLOSED GARAGE JUST TO CHECK THE TANK BEFORE I BROUGHT IT IN SHOULD THERE BE ANY PROBLEMS. I WAS CONFIDENT ENOUGH TO REMAIN ON THE BIKE AND REMOVED THE KEY FROM THE IGNITION TO UNLOCK THE FUEL TANK. WHILE SITTING ON THE BIKE WITH MY HELMET, JACKET, AND SUNGLASSES STILL ON I INSERTED THE KEY INTO THE CAP AND OPENED IT. UPON UNLOCKING, THE CAP BURST FULL OPEN AND INSTANTLY FUEL SHOWERED ME AND THE INSTRUMENT PANEL OF THE BIKE AS IF A HOT RADIATOR CAP WAS OPENED. RELIEVING THE PRESSURE IN THE TANK ALLOW THE FUEL TO SPONTANEOUSLY BOIL . AFTERWARDS I WOULD ESTIMATE THAT 1.5 TO 2 GALLONS CAME OUT OF THE TANK IN A MATTER OF 1 SECOND. COVERED IN FUEL I QUICKLY JUMPED OFF THE BIKE STILL HOLDING THE KEY WHICH BROKE OFF IN MY HAND. MY CONCERN IS FOR OTHER RIDERS THAT MAY ENCOUNTER THIS PROBLEM. I TAKING THE BIKE TO GET THE TANK VENT SYSTEM REPAIRED BY A HONDA DEALER. THIS IS EXTREMELY DANGEROUS AS THE VENT SYSTEM HAS FAILED TO AN UNSAFE CONDITION. *TR;