Fuel Filter May Clog and Cause Engine Stall – 2018-2019 Honda CRF1100L Africa Twin Adventure Sports & 2020 CRF1100L Africa Twin Adventure Sports Motorcycles

December 17, 2020 NHTSA CAMPAIGN NUMBER: 20V797000

Fuel Filter May Clog and Cause Engine Stall

An engine stall can increase the risk of a crash or injury.

 

NHTSA Campaign Number: 20V797

Manufacturer Honda (American Honda Motor Co.)

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 2,690

 

Summary

Honda (American Honda Motor Co.) is recalling certain 2018-2019 Africa Twin Adventure Sports (CRF1000L) and 2020 Africa Twin Adventure Sports (CRF1100L) motorcycles. Contaminants inside the fuel tank may cause the fuel filter to clog, possibly resulting in an engine stall.

 

Remedy

Honda will notify owners, and dealers will drain and clean the fuel tank, and replace the fuel filter assembly, free of charge. The recall began on February 4, 2021. Owners may contact Honda customer service at 1-866-784-1870. Honda’s number for this recall is KL4.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Honda Motorcycle or Scooter has a Recall

 


CRF1000/1100 (AFRICA TWIN) – FUEL FILTER CLOGGING

 

BACKGROUND

On December 15, 2020, Honda issued a STOP SALE NOTICE in support of a SAFETY RECALL on ALL 2018-2019 CRF1000L2/D2 and CERTAIN 2020 CRF1100L4/D4 (Africa Twin Adventure

Sports) motorcycles to repair a fuel filter clogging issue. Contaminants present in the fuel tank can clog the fuel filter. A clogged fuel filter can cause the motorcycle’s engine to hesitate or stall, increasing the risk of a crash or injury.

ONLY Africa Twin Adventure Sports models (large capacity fuel tanks) are affected. Standard Africa Twin models are not affected.

This Service Bulletin includes the fuel tank cleaning procedure and fuel pump repair procedure (including supporting videos), parts information, and warranty template claim information.

Honda will notify customers with affected vehicles via letter in February 2021, advising to make an appointment with an authorized Honda dealer to perform the recall repair by cleaning the fuel tank and replacing specific components of the fuel pump.

 

AFFECTED UNITS

Any NEW or USED 2018-2019 CRF1000L2/D2 motorcycle.

Certain NEW or USED 2020 CRF1100L4/D4 motorcycles.

  • To search for applicable recalls on a specific unit, you MUST use Unit Information on iN.

 

DEALER INVENTORY

Effective December 15, 2020, YOU MUST NOT SELL any NEW OR USED 2018-2019 CRF1000L2/ D2 OR CERTAIN affected 2020 CRF1100L4/D4 Africa Twin Adventure Sports motorcycles until it has been repaired according to this Service Bulletin.

  • To search for applicable recalls on a specific unit, you MUST use Unit Information on iN.
  • To manage your affected inventory, you MUST use your dealer eResponsibility Report on iN.

 

PARTS INFORMATION

Parts are available through the normal parts ordering process.

PART NAME P/N QTY
*FUEL FILTER KIT 06160-MKK-305 1

 

*Kit includes: Suction Filter, Fuel Filter, Pressure Regulator Assy, Pressure Regulator O-ring,  Fuel Pump O-ring, Fuel Chamber, Fuel Pump Packing Base

 

RECALL REPAIR PROCEDURE

Follow the appropriate Service Manual and the written instructions in this Service Bulletin to perform the fuel tank cleaning procedure and recall repair.

In addition, two videos have been included to support the written instructions. These videos include tips to perform the fuel tank cleaning procedure and the fuel pump rebuild.

NOTE: Prior to starting the repair, carefully inspect the fuel tank for any external cosmetic damage and document any damage found.

NOTE: Take great care to protect the fuel tank and other painted surfaces of the motorcycle from damage while performing the repair.

 

Click the link below to view the fuel tank cleaning tips video.

https://honda.vo.llnwd.net/o10/5160/090111c081e573a0/Africa_Twin_Fuel_Pump_cleaning.html

 

1. Using a siphon pump or equivalent, remove all the fuel from the fuel tank.
Place removed fuel into a clean container as the fuel will be returned to the fuel tank once the repair is complete.

2. Following the Service Manual, remove the fuel tank from the motorcycle.

3. Be sure to place the fuel tank on a nonabrasive surface when cleaning the fuel tank to avoid cosmetic damage.

4. Plug the fuel vent tube and fuel outlet tube to avoid fuel leaks (as shown).

5. Add one gallon of the removed fuel back into the fuel tank to be used as part of the fuel tank cleaning procedure.

6. Place the fuel tank onto its front stay as shown. Rock the tank from front to back 40 times (front to back counts as one time), using the front stay of the tank as a pivot.

7. Place the fuel tank onto its back stay as shown. Rock the tank from side to side 20 times (side to side counts as one time), using the back stay of the tank as a pivot.

8. While resting on the back stay, position the fuel tank as shown. Rotate the top of the tank 360° counter clockwise 20 times, then rotate 360° clockwise 20 times.

9. Following the Service Manual, remove the fuel pump from the fuel tank.

NOTE: Be careful when removing the fuel pump due to possible excess pressure build up during the fuel tank cleaning procedure.

10. Carefully remove as much of the contaminated fuel as possible using a siphon pump or equivalent.

11. Stand the fuel tank up on its back stay and, using a baster, remove any leftover fuel and contaminants from the fuel tank.

NOTE: The one gallon of fuel used for the cleaning procedure will not be reused. Properly dispose of this fuel.

 

Click the link below to view the fuel pump rebuild tips video.

https://honda.vo.llnwd.net/o10/5160/090111c081e573a2/Africa_Twin_Fuel_Pump_Repair_Tips.html

 

12. Begin to disassemble the fuel pump by removing the screws [1], Black wire terminals [2], and stoppers [3]. Disconnect the White wire connector [4] and Blue wire connector [5].

NOTICE: When removing the screws, be sure to use a #2 Phillips head screwdriver with sufficient hand pressure to avoid damaging the screw heads.

13. Remove the fuel filter assembly [1] and
O-ring [2] from the fuel pump stay [3].

NOTICE: When removing the fuel filter assembly, it may be necessary to gently pry against both sides of the base of fuel pump to lift the assembly away from the base being careful not to damage the base or fuel filter assembly.

14. Remove the chamber [1] by releasing the tabs [2].

15. Remove the fuel pump [1] and O-ring [2].
Remove the suction filter [3] from the fuel pump. Remove the pressure regulator [4] and O-ring [5] from the fuel filter [6].

NOTE: It may be necessary to use pliers and a twisting motion to remove the pressure regulator from the fuel filter.

16. Press the tabs on both ends of the reserve sensor [2] then pull out the fuel filter [1].

17. Remove the suction filter [2] from the fuel pump [1].

NOTE: Make sure to not let foreign matter into the fuel pump suction or discharge ports.

18. Assemble the reserve sensor [2] to the new fuel filter [1] by sliding it until it locks in place.

19. Apply engine oil to a new O-ring [2].
Install the O-ring to new pressure regulator [1]. Install the pressure regulator into the fuel filter [3].

20. Remove the suction filter cover [1] from the new suction filter [2] to prevent damage to the suction filter cover during installation.

21. Position the suction filter so that it is aligned evenly with the fuel pump before applying pressure to seat it fully.

NOTE: Once the suction filter is installed, make sure there is no more than 0.5mm gap between the suction filter and the fuel pump body measured by a feeler gauge in the areas shown.

22. Install the suction filter cover [2] to the suction filter [1].

23. Apply engine oil to a new O-ring [1]. Install the O-ring to the fuel pump [2]. Install the fuel pump to the fuel filter. Align the Blue wire [3] with the fuel filter groove [4]. Lead the Black wire [5] through the hole [6] of the fuel filter as shown.

24. Set the Blue wire [1] through the groove [2] of the fuel filter [3] as shown. Install a new chamber [4].

25. Apply engine oil to a new O-ring. Install the O-ring [1] to the fuel pump stay [2].
Install the fuel filter assembly [3] by aligning the groove with the fuel pump stay tab.

NOTE: Completely seat the fuel filter assembly to the fuel pump base using hand pressure until the fuel pump stay tabs are aligned.

26. Install the stoppers [1], Black wire terminals [2], and fuel pump/reserve sensor terminal screws [3]. Tighten the fuel pump/reserve sensor terminal screws with a #2 Phillips head screwdriver to the specified torque below.

TORQUE: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) Connect the White wire connector [4] and Blue wire connector [5].

27. Install a new packing [1] onto the fuel pump unit [2].

NOTE: Be careful not to pinch any dirt or debris between the fuel pump unit and packing.

NOTE: Align the packing tab with the fuel pipe.

28. Using the Service Manual, re-install the fuel pump into the fuel tank, and re-install the fuel tank.

29. Re-fill the fuel tank with the fuel removed in the initial removal procedure.

NOTE: Add one gallon of additional fuel to compensate for the fuel used in the cleaning procedure.

 


DEFECT INFORMATION REPORT

 

Name of manufacturer:

Honda Motor Co., Ltd., Kumamoto Factory

 

Manufacturer’s agent:

Jeff Chang
American Honda Motor Co., Inc.
1919 Torrance Blvd.
Torrance, CA 90501-2746

 

Identification of potentially affected vehicles:

Make/Model Model Year Dates of Manufacture Number of Vehicles
Honda CRF1000L Africa Twin Adventure Sports 2018 03/20/2018 – 07/24/2018 1,292
Honda CRF1000L Africa Twin  Adventure Sports 2019 08/30/2018 – 03/27/2019 877
Honda CRF1100L Africa Twin  Adventure Sports 2020 08/28/2019 – 05/27/2020 521

 

Description of the basis for the determination of the recall population:

The recall population was determined based on manufacturing records.  The production range reflects all possible vehicles that could experience the problem.

 

Description of how the vehicles being recalled differ from similar vehicles not included in the recall:

All vehicles produced within the dates of manufacture ranges specified above are affected.  As a process improvement, fuel tanks now undergo an additional cleaning process to remove contaminants after welding has been completed.

 

Identification of affected components:

Component: Fuel Filter Assembly

Part No.:

Model Part Number
CRF1000L 16700-MKK-D22
CRF1100L 16700-MKK-E21

 

Country of Origin: Japan

Manufacturer: Mitsubishi Electric Corporation

 

Total number of potentially affected vehicles: 2,690

 

Percentage of affected vehicles that contain the defect: 100%

 

Defect description:

Zinc oxide, generated in the fuel tank manufacturing/welding process, can contaminate the fuel and clog the fuel filter. Under these conditions, the engine could potentially stall, increasing the risk of a crash.

 

Chronology:

August – September 2018

Honda received a report of engine hesitation/stalling under acceleration with a clogged fuel filter and debris in the fuel tank, respectively, in the U.S. and Canada markets and began an investigation.

 

October – December 2018

Investigations were closed, as Honda was unable to identify the root cause.

 

March 28, 2019

Honda received a report of contaminated fuel in the fuel tank from the Mexico market.

 

June – July 2019

Honda received initial reports of engine stalling/hesitation from the UK, Italy, and Japan markets.

 

August 2019

Honda received three reports for engine stalling/hesitation in the U.S. One report identified a clogged fuel filter and the other two reports identified fuel pump failure.

 

October 2019

Honda received two additional reports of failed fuel pumps in the U.S.

 

June – December 2019

Honda investigated and analyzed the issues but did not identify a root cause.

 

January – May 2020

Honda identified that zinc oxide was present in the fuel tank as a result of different welding methods, and undertook further investigation.

 

March – May 2020

Honda received three additional reports for engine stalling/hesitation that were related to, respectively, clogged fuel filter causing engine bogging and stalling and a failed fuel pump in the U.S.

 

June – August 2020

Honda received 18 additional claims and reports on the issue in the North American and European markets.

 

September – November 2020

Honda analyzed and reviewed the increase in occurrences to identify the population of potentially affected vehicles.

 

December 10, 2020

Honda determined that a defect related to motor vehicle safety exists and decided to conduct a safety recall.

As of December 10, 2020, Honda has received 180 warranty claims, 74 field reports, and no reports of crashes or injuries related to this issue.

 

Program for remedying the defect:

Registered owners of all affected vehicles will be contacted by mail and asked to bring their vehicle to an authorized Honda motorcycle dealer. The dealer will drain, clean the fuel tank, and replace the fuel filter assembly, for free.

Owners who have paid to have these repairs completed at their own expense will be eligible for reimbursement, in accord with the recall reimbursement plan on file with NHTSA.

 

The notification date to dealers: December 15, 2020

The estimated date to start notifications to owners: February 15, 2021

 

Representative copies of all notices, bulletins and other communications:

A copy of the dealer service bulletin, the final customer notification letter and other dealer communication will be submitted to your office as soon as possible.

A draft of the owner notification letter will be submitted to your office as soon as possible.

 

Manufacturer’s campaign number: KL4

 


 

 


3 Affected Products

Vehicles

MAKE MODEL YEAR
HONDA CRF1000L 2018-2019
HONDA CRF1100L 2020

 


9 Associated Documents

Remedy Instructions and TSB

RCRIT-20V797-9498.pdf 2206.312KB

RCRIT-20V797-9498

 


Recall Acknowledgement

RCAK-20V797-7045.pdf 267.947KB

RCAK-20V797-7045

 


Manufacturer Notices(to Dealers,etc) – STOP SALE NOTICE: 2018-2019 CRF1000L2/D2 and 2020 CRF1100L4/D4 (AFRICA TWIN ADVENTURE SPORTS MODELS)

RCMN-20V797-8397.pdf 50.807KB

RCMN-20V797-8397

 


Defect Notice 573 Report

RCLRPT-20V797-6560.PDF 215.823KB

RCLRPT-20V797-6560

 


Miscellaneous Document – Part 573, Defect Information Report

RMISC-20V797-5204.pdf 242.001KB

RMISC-20V797-5204

 


Recall Quarterly Report #1, 2021-1

RCLQRT-20V797-7844.PDF 211.148KB

RCLQRT-20V797-7844

 


Remedy Instructions and TSB

RCRIT-20V797-0876.pdf 2111.614KB

RCRIT-20V797-0876

 


Manufacturer Notices(to Dealers,etc)- MULTIPLE MODEL: CRF1000/1100 #1 – FUEL FILTER CLOGGING IS NOW AVAILABLE

RCMN-20V797-0129.pdf 39.782KB

RCMN-20V797-0129

 


Recall Quarterly Report #2, 2021-2

RCLQRT-20V797-1856.PDF 211.25KB

RCLQRT-20V797-1856

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V797&docType=RCL

 


1 Associated Investigation

Clogged fuel filter causing a stall.
NHTSA ID: PE20013
Dated opened: August 10, 2020

The Office of Defects Investigation (ODI) is opening this Preliminary Evaluation (PE) on model year (MY) 2018 – 2020 Honda African Twin (CRF 1000 – 1100) motorcycles based on allegations of a sudden loss of power as a result of an engine stall.

ODI is aware of 26 consumer complaints alleging a stalling condition on the subject motorcycles. Many consumers allege the motorcycle stalled suddenly while riding. While speeds vary, most consumers allege the stalling occurred at highway speeds. This stalling condition is allegedly caused by clogged fuel filters. The subject vehicle fuel filters are becoming contaminated with zinc-oxide (corrosion). The corrosion is coming from the inside of the fuel tank, along the end seam of a joint weld. The corrosion clogs the fuel filter, restricts fuel flow to the engine, and subsequently causes a sudden engine stall. Additionally, ODI has received multiple manufacturer field reports describing stalling due to clogged fuel filters.

During complainant interviews, ODI learned that the bike can sometimes be restarted after the initial stall. However, several consumers described this restart as causing a false sense of security because after the restart, when trying to accelerate and merge into traffic, the bike quickly stalled again upon throttle demand. This time the rider is placed in the middle of traffic, potentially causing a crash or risk of injury.

ODI also learned that Honda implemented a fuel tank cleaning improvement campaign in mid-production (March 6, 2020) as a result of these failures. ODI is not aware of any complaints in the population of bikes manufactured after this production change was implemented.

A Preliminary Evaluation has been opened to determine the frequency of this failure mechanism and understand the conditions that might influence this malfunction on the subject vehicles.

The ODI reports cited above can be reviewed at:https://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11234560,11307903, 11316901, 11319660, 11324033, 11326571, 11327616, 11327924, 11328143, 11328156,11328160, 11328215,11328216, 11328220, 11329323, 11329491, 11329728, 11329851, 11329888, 11329890, 11330442, 11332003, 11337202, 11337739, 11337865, 11337887


 

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