Suzuki K8 gsx1300r Referenzhandbuch

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MOTORCYCLE / ATV DIVISION 4 - STROKE

GS/GSX/GSX-R BULLETIN NO. 183

DATE: 6/6/2008

SUBJECT: RECALL CAMPAIGN - IGNITION SWITCH INSPECTION/

REPLACEMENT

AFFECTED UNITS: CERTAIN 2008 GSX1300RK8 MOTORCYCLES

REFERENCE: GSX1300R SERVICE MANUAL (PN 99500-39350-03E)

ATTACHMENT: CUSTOMER LETTER

WHAT IS THE PROBLEM?

This notice is sent to you in accordance with the requirements of the National Traffic and Motor

Vehicle Safety Act.

Suzuki Motor Corporation has determined that certain GSX1300RK8 motorcycles may have

the ignition switch lead wire improperly routed. Handlebar movement can result in abnormal

flexing and damage to the ignition switch lead wire. Damage to the ignition switch lead wire

can result in intermittent or complete loss of electrical power, which can result in loss of

lighting and/or stalling of the engine. This could result in a crash.

SAFETY RECALL CAMPAIGN #2A05

CERTAIN 2008 GSX1300RK8 MOTORCYCLES

IGNITION SWITCH INSPECTION/REPLACEMENT

WHAT WILL SUZUKI DO?

Suzuki is recalling affected units for inspection of the ignition switch lead wire routing. You

will correctly reroute or replace the ignition switch lead wire portion of the ignition switch

assembly. Instructions are provided in this bulletin for correct routing and replacement of the

ignition switch lead wire to prevent failure.

DO NOT DELIVER an affected NEW or USED 2008 GSX1300RK8 motorcycle to a customer

until you have completed, or verified completion of, the procedures in this bulletin.

It is a violation of Federal law to deliver any new vehicle subject to a safety recall campaign

under a sale or lease until the defect or noncompliance has been corrected. You must verify

this on the Suzuki "Certificate of Vehicle Pre-Delivery" form, which is to be completed for

all new and used vehicle sales.

STOP DELIVERY OF 2008 GSX1300RK8 MOTORCYCLES IMMEDIATELY

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AFFECTED UNIT VIN RANGES:

The VIN ranges of the affected GSX1300RK8 models are listed below. Confirmation of an

affected unit can be checked on Suzuki Connect.

NOTE:

If your dealership has sold an affected GSX1300RK8 to a customer, but you have not yet

submitted sales 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 these customers, you must immediately notify these

customers of the recall campaign.

VERIFY THE UNIT REQUIRES THE RECALL REPAIR:

Before performing the recall inspection to a unit, verify that the inspection needs to be done.

There are two ways to identify a unit that has already been repaired.

1. Check the repair status by checking the Vehicle History in the Suzuki Connect Service

Menu. If the repair needs to be performed to the motorcycle, you will see the message

“CAMPAIGN NOT YET PERFORMED” displayed and the ignition switch lead wire routing

will need to be inspected. Refer to the inspection procedure in this bulletin.

2. Inspect the right side of the frame head tube for an identification punch mark located

at the beginning of the Vehicle Identification Number. If a punch mark is present the

recall repair has already been performed.

JS1GX72A382100028

Punch mark

WHAT YOUR DEALERSHIP WILL DO:

Notify your staff.

Contact your customers; please telephone all of your customers and inform them of the need

to stop riding their motorcycles until the ignition switch lead wire inspection/replacement has

been completed.

Starting VIN Ending VIN

JS1GX72A*82100020 JS1GX72A*82111031

JS1GX72A*82111267 n/a

JS1GX72A*82111546 JS1GX72A*82111605

JS1GX72A*82111700 n/a

JS1GX72A*82111726 JS1GX72A*82111753

JS1GX72A*82111755 JS1GX72A*82111756

JS1GX72A*82111759 n/a

JS1GX72A*82111766 JS1GX72A*82111773

JS1GX72A*82111775 n/a

JS1GX72A*82111785 JS1GX72A*82111943

JS1GX72A*82111945 JS1GX72A*82112167

JS1GX72A*82112169 n/a

JS1GX72A*82112171 JS1GX72A*82112289

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CUSTOMER NOTIFICATION:

In the Safety Recall Campaign letter that will be mailed on June 10, 2008 (see attachment),

customers are being advised to contact the Suzuki dealer where they purchased their affected

unit to schedule an appointment to have the ignition switch lead wire inspected. As some

customers may have moved to other communities since their motorcycle purchase, you may

also receive calls from customers who purchased their Suzuki elsewhere. Once you are

contacted by the owner of an affected unit, please arrange an appointment for a recall

inspection. Also, advise your customers that the Safety Recall Campaign service will be

performed at no cost to them for parts and labor.

IMPORTANT:

Successful completion of this safety recall campaign depends on your efforts. It is your

responsibility to repair any affected GSX1300RK8 within the VIN range at no cost to the

customer for recall service 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 (800/756-3251) to discuss possible solutions.

ORDERING PARTS FOR THE SAFETY RECALL CAMPAIGN:

You will be responsible for ordering the ignition switch kit for any customer's motorcycle

which had an incorrectly routed ignition switch lead wire. Order the switch kit using your

normal parts ordering methods. New, unsold units at your dealership will not require a

replacement ignition switch kit. Parts are currently available for this campaign.

SPECIAL TOOL AUTO-SHIPMENT

The special tool needed to disassemble the lock cylinder assembly will be auto-shipped

separately at no cost to your dealership during the week of June 9, 2008.

IGNITION SWITCH LEAD WIRE INSPECTION, REROUTING OR REPLACEMENT STEPS

Ignition Switch Set PN 99103-11237 Dealer Cost-$85.03

Description Qty Note

1 Ignition Switch 1

2 Screws 2 Mounted on Ignition Switch

3 Bolt, M8 2 Torx head, Pre-coated bolt

4 Cap 2

New Unsold Unit (Dealer Inventory)

Customer Unit (Sold) / Dealer Demo Unit

Incorrect

Reroute (page 5)

Replace Ignition Switch

(page 6)

Inspect Routing (page 4) Punch Mark VIN (page 8)

Punch Mark VIN (page 8)

Punch Mark VIN (page 8)Inspect Routing (page 4)

Punch Mark VIN (page 8)

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INSPECT ROUTING

1. Remove the upper and lower meter panels (refer to Service Manual page 9D-15).

2. Check if the ignition switch lead wire is clamped and routed correctly. Incorrect positions

are shown in Figures 1 and 2. Correct routing and clamping is shown in Figures 3 and 4

on page 5.

Figure 1

Incorrect

Position Incorrect Gray Tape

Position

Gray tape is not

visible on both

sides of clamp

-or-

Gray tape is not

positioned beneath

clamp

Figure 2

Incorrect

Routing

Incorrect Routing

Ignition switch harness

is routed behind the

right switch harness.

Cowling

Brace

Side §§

§§

900

Ignition Switch

Lead Wire

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Figure 3

Correct

Figure 4

REROUTING

1. Reroute the ignition switch lead wire correctly (Figure 3 and Figure 4). The ignition switch

lead wire should not be covered by the other wire harnesses.

2. Turn the handlebars back and forth to verify that the steering operates smoothly and the

wiring harness does not become kinked or pinched.

3. Proceed to PUNCH MARK AT VIN on page 8.

900900

Correct Routing

The ignition switch

lead wire is routed in

front of the right

switch lead wire.

Front side

ªª

Correct Gray Tape

Location

Gray tape is visible on

both sides of clamp.

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Remove the ignition switch assembly

from the motorcycle (refer to Service

Manual page 1H-12).

Remove the two black plastic covers to

access the cylinder cap mounting bolts

(Figure 5).

Note: The black plastic covers will not be

reused.

Secure the mount area (bottom) of the

ignition switch in a vise (Figure 6).

NOTE:

Turn the ignition switch to the OFF posi-

tion and remove the key from the ignition

switch before disassembling the switch.

Remove the two "break-off"

screws from the ignition switch using the

special screwdriver. Set the stepped end

of the sleeve on the special screwdriver

facing toward the "break-off" screws

(Figure 7). Strike the special screwdriver

5 to 7 times with a hammer to produce a

deep enough groove on the screw head

for the screwdriver to work properly

(Figure 6). Pay attention not to hit other

parts with the hammer. Turn to remove

the "break-off" screws in a counter-

clockwise direction. If the groove be-

comes damaged, make another groove

at a 90o angle to the original groove.

Remove the ignition switch from the vise

and hold it upright over the workbench

and carefully remove the cylinder cap

(Figure 8).

NOTE:

Pay close attention to the order and

orientation of the ignition switch parts

during disassembly.

REPLACEMENT OF IGNITION SWITCH (Customer Sold Units/Dealer Demo Units- Only If

Inspection Shows Incorrect Routing And Unit Has Been Ridden)

New Ignition Switch Disassembly

Figure 5

Figure 6

Figure 7

Figure 8

Cylinder

Cap

When striking an object with a hammer

parts can fly up, hitting you in the eyes

and cause blindness or injury.

Always wear eye protection when us-

ing a hammer.

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Remove the shutter. The shutter may

come off the ignition switch in the cylin-

der cap, but is not secured to the cap.

Remove the rotor and spring from the

ignition switch. When the rotor is re-

moved, the spring may be attached to the

rotor, but it will not be secured.

The cylinder cap, shutter, rotor, and

spring will be used for reassembly of the

new switch. Keep these parts in a safe,

clean location.

Attach a warranty parts tag to the origi-

nal ignition switch body and retain for

TSM inspection.

Using a philips screwdriver, carefully

remove the "break-off" screws from the

new ignition switch (these screws are

hand-tightened) and keep them for reas-

sembly of the new ignition switch.

Remove the cylinder cap, shutter, rotor,

and spring. These parts will not be reused

for reassembly of the new switch.

Begin reassembly using the main body of

the new ignition switch. The new (recall

kit) ignition switch body can be identified

by the letter "A" at the end of the lot

number (Figure 10).

Set the spring from the original ignition

switch onto the projection in the new

ignition switch body (Figure 11).

Install the rotor from the original ignition

switch into the new ignition switch body.

There is only one correct position (Figure

12) to install the rotor into the ignition

switch body. Note the position of the

tumbler plates when the rotor is installed.

When installed in the correct position,

the rotor will drop into the new ignition

switch body smoothly and easily. Do not

force or push the rotor into the ignition

switch or damage may occur.

New Ignition Switch Disassembly

Figure 9

Spring

Shutter

Rotor

New Ignition Switch Reassembly

Figure 11

Spring

Figure 10

8513 A

Figure 12

Tumbler Plates

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Figure 14

Projections Hollows

Figure 13

Place the shutter from the original igni-

tion switch on the rotor, aligning and

placing the projections into the hollows

(Figure 13). The shutter can be aligned

one of two ways 180oapart. Either way

is correct.

Place the cylinder cap over the key

cylinder and hold it firmly in position.

Insert the ignition key and test the rota-

tion of the rotor. If the rotor does not turn

smoothly, remove the cap and check the

assembly, making any necessary correc-

tions. Repeat the procedure until the

rotor turns smoothly when using the key.

Secure the cylinder cap with the break-

off screws. Tighten the screws evenly

until the screw heads break off (Figure

14). Install the plastic caps (provided in

the kit) on the cylinder cap over the

break-off screws.

Install the ignition switch assembly (refer

to Service Manual page 1H-12). Be cer-

tain to use the pre-coated bolts provided

in the recall kit when installing the new

ignition switch.

Ignition Switch Mount Bolt:

13 N.m (1.3 kgf-m, 9.5 lb-ft)

Refer to Figure 3 and 4 on page 5 for

correct routing of the ignition switch lead

wire.

Turn the handlebars back and forth to

verify that the steering operates smoothly

and the wiring harness does not get

kinked or pinched.

After the inspection, rerouting, or re-

placement procedure is complete be cer-

tain to place an identification punch mark

on the frame at the beginning of the

Vehicle Identification Number (located

at the right side of the frame head tube)

as illustrated on page 2.

11.

12.

13.

PUNCH MARK AT VIN

10.

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WARRANTY REIMBURSEMENT & CLAIM INFORMATION:

Submit a warranty claim for each recall campaign service immediately upon completion of

the repair. This campaign requires you to file a warranty claim using the following information.

Short Form Claim:

Use the Short Form Claim for new, and customer owned units that require ignition switch lead

wire inspection and/or re-routing. Labor time is 0.3 hours.

Long Form Claim:

Use the Long Form Claim for customer owned units requiring ignition switch assembly

replacement or for units with additional time or parts required as approved by Tech-Line. Labor

time is 1.3 hours.

Suzuki Connect Long Form warranty claim entries with additional parts or labor require a prior

authorization (PAS) code from TECH-LINE or your Technical Service Manager, or the Suzuki

Connect system will not accept the claim.

RECALL CAMPAIGN

IGNITION SWITCH LEAD WIRE INSPECTION, REROUTE

Short Form Instructions

GENERAL

CLAIM NUMBER: XXXXX,X (Dealer enters number)

ENTRY TYPE: Model, Frame or Control Sequence

(Dealer Chooses)

MODEL: GSX1300RK8

FRAME: X821XXXXX

REPAIR DATE: Enter date of repair

MILEAGE: Enter mileage on unit

CAMPAIGN NUMBER: 2A05

RECALL CAMPAIGN

IGNITION SWITCH LEAD WIRE INSPECTION AND REPLACEMENT

Long Form Instructions

GENERAL

CLAIM NUMBER: XXXXX,X (Dealer enters number)

ENTRY TYPE: Model, Frame or Control Sequence

(Dealer Chooses)

MODEL: GSX1300RK8

FRAME: X821XXXXX

REPAIR DATE: Enter date of repair

MILEAGE: Enter mileage on unit

CAMPAIGN NUMBER: 2A05

LABOR HOURS: 1.3 hrs

PARTS

REPLACEMENT PART NUMBER: 99103-11237 QTY: 1

FAILURE DESCRIPTION

DESCRIPTION OF FAILURE: Replace Ignition Switch Assembly per

Service Bulletin GS-GSX-GSXR-GSF 183

SUBLET

SUBLET AMOUNT: as approved by TECH-LINE

NOTE: Do not use the "$" when entering an amount

SUBLET REFERENCE NUMBER: 2A05

SUBLET REPAIR DESCRIPTION:

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CUSTOMER SATISFACTION:

We understand and 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 and satisfaction.

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 campaign may

cause them.

AFFECTED DEPARTMENTS:

The following departments in your dealership should be notified of this information:

⌧⌧

⌧Management ⌧⌧

⌧⌧

⌧

Service ⌧⌧

⌧⌧

⌧

Warranty ⌧⌧

⌧⌧

⌧

Sales ⌧⌧

⌧⌧

⌧

Parts ⌧⌧

⌧⌧

⌧

Accessories

American Suzuki Motor Corporation

Technical Service Department

Motorcycle / ATV

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