On certain 4WD vehicles, the electric shift transfer case may not fully engage into gear when the operator moves the transfer case selector switch. This could cause the transfer case to end up in the neutral position unexpectedly and allow the vehicle to roll away if the parking brake is not applied.
Safety Risk
No risk description available.
Remedy
Dealers will reprogram the transfer case control module.
Certain vehicles were built with automatic transmission cooler hoses (in and out) that may not have met specific winner wall thickness requirements in the manufacturing process. Over time, these hoses may deteriorate and leak automatic transmission fluid. Should leaking transmission fluid contact a hot exhaust pipe, a fire could occur.
Safety Risk
No risk description available.
Remedy
Dealers will replace the hose assembly for the automatic transmission oil cooler.
On certain vehicles equipped with a manual transmission, the clutch pressure line may leak in the area of its connection with the clutch slave cylinder. This may result in loss of power assist to the steering or clutch system. If the hydraulic fluid comes in contact with hot exhaust components a fire could result.
Safety Risk
No risk description available.
Remedy
Clutch pressure line will be replaced and an additional bracket will be installed.
On certain vehicles, when the clutch lever is released to the friction point, but not completely to fully engaged (slipping the clutch), strung clutch disc judder may occur at the higher engine rpm used for rapid starts. The stress created can cause the clutch outer to fail, which in turn could cause several large sections to crack and eventually separate from the clutch outer. This could potentially cause rear wheel lock-up, engine stoppage or crankcase leaking. Also, the clutch lever shaft does not have sufficient strength and may fail when the clutch is applied. As a result, the rider would not be able to release the clutch.
Safety Risk
No risk description available.
Remedy
Dealers will install a new, redesigned clutch kit and a new redesigned clutch lift lever.
On certain vehicles, water contamination of the automatic transmission oil can lead to various failure modes of the transmission. One of these failure modes results in incorrect operation of the park lock function that could allow a vehicle to roll away if parked without the handbrake properly set.
Safety Risk
No risk description available.
Remedy
Dealers will check the park lock function; reposition the automatic transmission breather tube; and test the automatic transmission fluid and flush if necessary.
On certain vehicles, the Powertrain Control Module may allow the vehicle to exceed the design intent top speed. At these extreme speeds. the vehicle may be capable of exceeding the speed rating of the tires. This could lead to tire failure and at these extreme speeds, may result in a crash.
Safety Risk
No risk description available.
Remedy
Powertrain Control Module will be reprogrammed with the latest calibration.
Certain vehicles do not comply with the requirements of CMVSS 114 - Locking System. When a driver attempts to shift from 5th gear to reverse, a shift inhibitor causes the transmission to be mechanically in 4th gear even though the shift lever indicates reverse gear. In this situation, the key can be removed from the ignition while the transmission is in a forward gear, which is not permitted by the standard.
Safety Risk
No risk description available.
Remedy
Dealers will disable the 5th/Reverse Inhibitor by removing a retaining pin and replace the shifter assembly.
On certain vehicles, the transaxle shift cable retainer clip may be missing or improperly seated. Without the retainer clip, the cable can slip out of its bracket and the transaxle lever may not move along with the shift lever. The driver may put the shift lever in Park, but the transaxle may be in Reverse or Neutral. Unexpected movement of the vehicle could cause a crash without prior warning.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the shift cable retainer clip to verify proper installation, and, if necessary, replace the cable.
On certain vehicles, there is the possibility that the sprag housing bolts will become loose and may cause consequential engine damage and possible driveline seizure. This could result in loss of vehicle control and a possible crash.
On certain vehicles, the spring in the cam chain tension adjuster can break. This can cause excessive slack in the cam chain and allow the cam chain to jump to the wrong position, causing severe engine damage and sudden engine failure. Sudden engine failure while riding can cause rear wheel lockup and loss of vehicle control.
Safety Risk
No risk description available.
Remedy
Screw-type cam chain tension adjuster will be replaced with a ratchet-type cam chain tension adjuster.
On certain vehicles, the shift cable locking plate may break, allowing the driver to shift into the Park position but making it very difficult to shift from the Park position. The gear shift lever and the PRNDL indicator may move, but the transmission will not shift from the Park position. If the driver were over time to manipulate the gear shift lever out of Park, the gear indicated on the PRNDL display may differ from the gear actually engaged.
Safety Risk
No risk description available.
Remedy
Automatic transmission shift cable lock plate will be replaced.
Certain motorcycles were built with a rear wheel sprocket that could break. This condition could cause the rider to lose power, lose control, or be struck by debris; any of these occurences could result in a possible crash and injury.
Safety Risk
No risk description available.
Remedy
Dealers will install a new rear wheel sprocket and belt.
On certain vehicles equipped with the Active Cornering Enhancement (ACE) system, the left side engine idler pulley can fracture and ultimately fail. This would cause the pulley to throw off the serpentine belt, which can result in loss of auxiliary functions (power steering, water pump, alternator, air conditioning and ACE). Loss of steering assist would require increased steering effort and create the risk of a vehicle crash.
Safety Risk
No risk description available.
Remedy
Plastic idler pulley will be removed and replaced with a newly designed steel pulley.
On certain vehicles, improper heat treatment during assembly could result in inadequate strength in certain areas of the rear axle shafts. After extended use of the vehicle, the rear axle shafts may fail or break. This could result in rear wheel separation and a possible crash without prior warning.
Safety Risk
No risk description available.
Remedy
Rear axle hub will be inspected and replaced if necessary.
On certain vehicles equipped with an manual transmission, the clutch pedal position switch plunger could contact the steering column boot and thereby not be able to extend when the clutch pedal is depressed. In this condition, the vehicle can be started with the transaxle in gear (not in neutral) without the clutch pedal depressed. If the driver is not applying the brake, the vehicle may move unexpectedly and a crash could occur.
Safety Risk
No risk description available.
Remedy
Dealers will install a shield to prevent contact between the column boot and the clutch pedal position switch.
Certain vehicles may be inadvertently left in reverse when the operator places the shift lever in the "Park" position. Should this occur, unintentional rearward movement of the vehicle could result.
Safety Risk
No risk description available.
Remedy
The steel manual valve in the transmission will be replaced with an aluminum version that will provide immediate feedback of reverse engagement to operators if they do not place the shift lever in gated park.
On certain motorcycles, the chain may fracture due to an inappropriate heat treatment process during manufacture. This would cause loss of drive and vehicle instability resulting in a possible crash without prior warning.
On certain motorcycles, the back torque limiter in the clutch may malfunction and allow the clutch to slip, or not re-engage after a shift. This sudden non-engagement of the clutch might cause the rider to lose control of the vehicle, possibly resulting in a crash.
Safety Risk
No risk description available.
Remedy
The clutch hub nut and back torque limiter springs will be replaced on affected vehicles.
On certainve vehicles equipped with automatic transmissions, he transmission shift cable may have an timproperly crimped end rod(s). A below specification crimp load on an end rod could, over time, allow the shift cable to be pulled out of the end rod. This would result in the driver losing the ability to change gears and the transmission would remain in the last gear selected prior to the detachment and the gear selector may not indicate the proper gear. With a detached transmission shift cable, the vehicle may move in a direction not anticipated by the driver, and a crash could occur without prior warning.
Safety Risk
No risk description available.
Remedy
A new shift cable will be installed on affected vehicles.
On certain vehicles, the transmission case bolt which allows service access to disconnect the differential from the transmission could loosen and fall out. If the bolt falls out, the extension shaft could disengage from the differential, disconnecting the drive train between the transmission and the differential. This could cause the vehicle to lose power to the drive wheels without warning. Also, shifting to the PARK position would not lock the wheels, and a parked vehicle could move unexpectedly if the parking brake is not set.
Safety Risk
No risk description available.
Remedy
An updated transmission case bolt (with an o-ring instead of thread lock/sealer) will be installed on affected vehicles.
