VEHICLE DESCRIPTION: MOTORCYCLES. WHEN THE CLUTCH LEVER IS RELEASED TO THE FRICTION POINT, BUT THE LEVER IS NOT COMPLETELY RELEASED TO FULLY ENGAGE THE CLUTCH, STRONG CLUTCH DISK VIBRATION MAY OCCUR AT THE HIGHER ENGINE RPMS USED FOR RAPID OR RACE-TYPE STARTS. THIS STRESS CAN CAUSE THE CLUTCH TO FAIL.
Safety Risk
THIS FAILURE RESULTS IN SEVERAL LARGE SECTIONS CRACKING AND EVENTUALLY SEPARATING FROM THE CLUTCH OUTER. IF THIS OCCURS, REAR LOCK-UP IS POSSIBLE IF A BROKEN PIECE IS CAUGHT IN THE PRIMARY DRIVE GEAR. ALSO, THE ENGINE COULD LOSE PRIMARY IGNITION AND STOP SUDDENLY IF A BROKEN PIECE DAMAGES THE PULSAR ROTOR; OR ENGINE OIL COULD LEAK FROM THE CRANKCASE, IF A BROKEN PIECE IS FORCED THROUGH THE CRANKCASE. THE SPILLED OIL COULD CAUSE THE REAR WHEEL TO LOSE TRACTION AND THE MOTORCYCLE COULD CRASH.
Remedy
DEALERS WILL INSTALL A CLUTCH KIT THAT INCLUDES A REDESIGNED OUTER CLUTCH BASKET, JUDDER SPRING, CLUTCH LIFTER LEVER, AND OTHER PARTS INTENDED TO REDUCE STRESS ON THE CLUTCH.
VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH MANUAL TRANSMISSIONS. THE CLUTCH MASTER CYLINDER MAY HAVE BEEN BUILT WITH AN INCORRECT RETAINING RING.
Safety Risk
THIS MAY NOT ALLOW THE CLUTCH SYSTEM TO DISENGAGE THE CLUTCH WHEN THE CLUTCH PEDAL IS DEPRESSED, RESULTING IN UNINTENTIONAL VEHICLE MOVEMENT, INCREASED STOPPING DISTANCES, ENGINE STALLS, AND DIFFICULTY IN SHIFTING.
Remedy
DEALERS WILL REPLACE THE HYDRAULIC CLUTCH MASTER CYLINDER WITH A NEW CYLINDER.
VEHICLE DESCRIPTION: PICKUP TRUCKS EQUIPPED WITH GASOLINE ENGINES AND MANUAL TRANSMISSIONS. THE UNDERBODY HYDRAULIC CLUTCH LINE HEAT SHIELD IS TOO SHORT, ALLOWING THE PLASTIC CLUTCH LINE MATERIAL TO BE DIRECTLY EXPOSED TO EXHAUST TEMPERATURES. IT IS POSSIBLE TO EXCEED THE MELTING TEMPERATURE OF THE CLUTCH LINE MATERIAL.
Safety Risk
IF THE LINE MELTS, HYDRAULIC FLUID CAN LEAK ONTO THE VEHICLE EXHAUST AND CAUSE AN UNDERBODY FIRE.
Remedy
DEALERS WILL INSTALL THE PROPER LENGTH HEAT SHIELD.
VEHICLE DESCRIPTION: PICKUP TRUCKS EQUIPPED WITH MANUAL TRANSMISSION, V10 ENGINES AND FOUR-WHEEL-DRIVE TRANSFER CASES. UNDER SUSTAINED MAXIMUM RATED VEHICLE LOAD, WHILE DRIVING UP A STEEP GRADE IN FOUR-WHEEL-DRIVE LOW RANGE IN HOT AMBIENT CONDITIONS, THE LOCAL EXHAUST TEMPERATURE PROXIMATE TO THE HYDRAULIC CLUTCH LINE CAN GENERATE LINE TEMPERATURES THAT EXCEED THE TEMPERATURE LIMIT OF THE CLUTCH LINE MATERIAL. IF THIS CONDITION OCCURS AND THE CLUTCH IS DEPRESSED, THE LINE COULD RUPTURE.
Safety Risk
THE FLUID COULD IGNITE ON THE HOT EXHAUST POSSIBLY RESULTING IN A VEHICLE FIRE.
Remedy
DEALERS WILL REPLACE THE HYDRAULIC CLUTCH ASSEMBLY.
