Yamaha is recalling its three-cylinder FZ-09, FJ-09 and XSR900 models from 2015 to 2017 because their handlebars may come loose. The recall affects a combined 22,433 units in the U.S.
According to documents released by the National Highway Traffic Safety Administration, the lower handlebar holders (highlighted in yellow in the diagram below from recall documents from Yamaha) may have been improperly painted and their stud bolts may lack adequate thread-locking agents. If the handlebars are subjected to a strong external impact, the paint on the bottom of the lower handlebar holders may wear, creating enough of a gap that could allow the stud bolts to loosen from engine vibration. This may cause the studs to loosen or even completely fall off, causing the handlebar to come loose.
The problem was first identified during quality control review and testing.
Yamaha dealers will replace the lower handlebar holders on recalled units with a new part that has undergone a different paint and thread-lock application process. The new parts do not have paint on the bottom contact surface so there is no risk of creating excess clearance from paint wearing away. The stud bolts have also been treated with a dry-type thread locking agent applied by machine.