Suzuki is recalling 68,344 motorcycles and scooters, affecting 11 different models from model years 2008 to 2012 because of a problem with their circuit boards that may prevent their batteries from charging properly. The recall supersedes a previous recall from 2011 that affected 73,426 motorcycles.
The new recall affects the following models:
According to documents released by the National Highway Traffic Safety Administration, the regulator/rectifier power module circuit boards on the affected motorcycles may absorb moisture when stored in high humidity conditions. This can reduce the strength of the adhesive attaching the circuit boards to the aluminum cases. Heat generated by the circuit boards may cause them to deform and lift off the cases, increasing heat levels preventing sufficient charging current to the batteries.
Suzuki first received a report of a motorcycle from Indonesia failing to start because of a discharged battery in October 2010. In January 2011, Suzuki received the faulty motorcycle and found signs of deformation from heat in the rectifier. As further reports came in, Suzuki discovered the weakness in the adhesive but ruled it was caused by severe usage conditions such as maintaining a high engine speed.
In December 2011, Suzuki was able to duplicate the problem through exposure to a high humidity conditions. To compensate for this, Suzuki changed its manufacturing process by storing power modules in a humidity-controlled environment until needed for rectifier assembly.
The problem continued, however, and by November 2012, Suzuki began exploring other possible causes. In September 2015, Suzuki decided to re-evaluate the maximum temperature tolerance for the adhesive when exposed to high humidity conditions. By December, Suzuki was able to determine the maximum allowable temperature and found the rectifier on several motorcycles may exceed this limit.
Suzuki began the recall process on Jan. 9, 2016. By then, Suzuki had received more than 200 field reports including one from the U.S.
Suzuki dealers will replace the regulator/rectifier on affected motorcycles at no charge to the owners.