2019-2020 Honda CB500XA/CBR500RA ABS Modulator Inspection Recall

September 2, 2021 NHTSA CAMPAIGN NUMBER: 21V690000

ABS Modulator May Leak Brake Fluid

A brake fluid leak can reduce braking performance and increase the risk of a crash.

 

NHTSA Campaign Number: 21V690

Manufacturer Honda (American Honda Motor Co.)

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 262

 

Summary

Honda (American Honda Motor Co.) is recalling certain 2019-2020 CB500X and CBR500R ABS motorcycles. Excessive grease in the ABS modulator may collect debris, which can get stuck in the check valve and cause a brake fluid leak.

 

Remedy

Dealers will inspect the lot number on the ABS modulator, and replace the modulator as necessary, free of charge. Owner notification letters were mailed November 12, 2021. Owners may contact Honda Powersports customer service at 1-866-784-1870. Honda’s number for this recall is KM6.

 

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.nhtsa.gov.

 

Check if your Honda Motorcycle or Scooter has a Recall

 


Honda Motorcycle
Honda Motorcycle

 


Multiple Model – CB/CBR500 #1
September 2021

Service Bulletin

SAFETY RECALL

MULTIPLE MODEL CB500XA / CBR500RA – ABS BRAKE MODULATOR

 

BACKGROUND

Honda is launching a SAFETY RECALL on CERTAIN 2019-2020 CB500XA/CBR500RA vehicles to inspect the ABS Modulator for a potential defect that might cause the vehicle to increase front brake stroke and decrease the braking force.

 

AFFECTED UNITS

CERTAIN NEW or USED 2019-2020 CB500XA/CBR500RA.

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

 

DEALER INVENTORY

As of September 3, 2021, YOU MUST NOT SELL any affected NEW OR USED motorcycles listed in the AFFECTED UNIT section until it is inspected and repaired if necessary, 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, refer to eResponsibility Report on iN.

 

CUSTOMER NOTIFICATION

American Honda intends to mail customer letters to all owners of affected 2019-2020 CB500XA/ CBR500RA vehicles in October 2021. Customers will be informed that their vehicle may be affected by a safety related defect and will be advised to make an appointment with an authorized Honda dealer for inspection, and repair (if needed).

 

PARTS INFORMATION

Parts are available through the normal parts ordering process.

MODEL DESCRIPTION PART NUMBER QTY.
CB500XA *Modulator Set 06570-MKP-306 1
CBR500RA *Modulator Set 06570-MKP-305 1

 

* Modulator Set Includes: Modulator Assy. (Qty. 1), Washer, Oil Bolt (Qty. 4), Seal, Air Cleaner (Qty. 1)

 

DEALER REPAIR RESPONSIBILITY

  • Repairs must be performed by a qualified technician.
  • Performing this repair exactly as shown in Repair Procedure instructions is critical for the remedy to be effective. Carefully follow all instructions.
  • Service Management should inspect and confirm the repair.
  • Dealer submission of a warranty claim affirms this repair was properly performed.

 

If the first two characters are anything other than those listed in the table below, the modulator is GOOD.

The table represents the NO GOOD Lot Codes and Range represented on the ABS Modulator. Starting with the first two characters, if the first two characters are 9F, 9H, 9K, 9L or 9N, the modulator is NO GOOD and must be replaced.

If the modulator code begins with 9C, 9D or 9S, see the table below to determine if the modulator is NO GOOD.

If you are unsure whether the ABS Brake Modulator is good or no good, record the entire Lot Code from the modulator and contact TechLine for assistance.

Lot #

 

TEMPLATE CLAIM INFORMATION

After completing a recall repair, immediately submit one template claim per affected VIN using the appropriate template information.

MODEL RESULT TEMPLATE FLAT RATE
CB500XA INSPECTION ONLY KM6A 0.4
CB500XA INSPECT AND REPAIR KM6B* 2.6
CBR500RA INSPECTION ONLY KM6C 0.4
CBR500RA INSPECT AND REPAIR KM6D* 2.5

*Includes reimbursement for (1) bottle of Pro Honda DOT 4 brake fluid.

 

WARRANTY QUESTIONS

If you have any warranty administration questions relating to template claims and claim filing procedures, please contact: Powersports Warranty Online: iN > Service > Warranty & HondaCare > Warranty Connect Filing

 

TECHNICAL QUESTIONS

If you have any technical questions relating to the repair procedure, please contact: Powersports TechLine Online: iN > Service > TechLine > TechLine Connect Or call (800) 421-1900, option 9.

 

RECALL REPAIR IDENTIFICATION

Before you begin the repair procedure, verify that the unit has not already been repaired by searching Unit Information on iN.

 

RECALL INSPECTION PROCEDURE

The ABS Modulator is located on the right side of the motorcycle, for both the CB500XA and CBR500RA.

ABS Modulator

EX: CB500XA ABS Modulator

 

Remove the two screws [1] and release the tab [2] to remove the ABS Modulator cover [3].

ABS Modulator cover

 

Remove the two bolts [1] from the bottom of the ABS Modulator bracket.

ABS Modulator bracket

 

Slightly push the ABS Modulator bracket for- ward, towards the front of the motorcycle, and locate the Lot Code that is stamped on the right side of the ABS Modulator.

Slightly push the ABS Modulator bracket forward

 

Record the entire lot code and compare it to the table on page two of this service bulletin to determine if the ABS Modulator is Good or No Good. If Good, replace the removed parts and immediately file the appropriate template claim for inspection only. If No Good the ABS Modulator must be replaced.

Record the entire lot code

 

RECALL REPAIR PROCEDURE

If repair is needed, refer to the model specific Service Manual to replace the ABS Modula- tor. After repair immediately file the appropriate template claim for inspection and repair.

 


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 may be affected.  Vehicles produced outside the specified range were equipped with Anti-lock Braking System (ABS) modulators assembled with the appropriate amount of grease.

 

Identification of affected components:

Component: ABS Modulator
Part No.: CB500X: 57110-MKP-J81

CBR500R ABS: 57110-MKP-J01

Country of Origin: Japan
Manufacturer: Hitachi Astemo Ltd.

 

Defect description:

Excessive grease was applied to the O-ring of the reservoir piston of the ABS modulator. After continued use, foreign matter may adhere to the grease, which can be pinched in the check valve during braking and cause brake fluid to leak. If this occurs, the braking distance (without ABS activation) will increase, increasing the risk of a crash.

 

Chronology:

February – March 2021

Honda recalled certain 2020MY CRF1100A/D motorcycles globally for ABS modulators assembled with excessive grease. The U.S. market was not affected by this recall and NHTSA was notified in a Foreign Recall Notice (21F-022) submitted pursuant to 49 CFR 579.12. In parallel with the foreign recall, Honda continued its investigation into the impact of excessive grease application to the ABS modulator installed on other motorcycles as it was a common component and there was a report from the Italian market of a different motorcycle model with a similar complaint of reduced braking performance.

 

April – August 2021

Honda continued its investigation of several motorcycle models and the impact of excessive grease application on non-ABS braking performance. Based on certain characteristics such as vehicle weight, whether the excessive grease was applied to front or rear brake oil passages on the ABS modulator, and brake disc/caliper specifications, Honda confirmed the non-ABS braking performance for one family of motorcycles did not meet internal specifications.

 

August 26, 2021

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

As of August 26, 2021, Honda has not received any warranty claims, field reports, or reports of crashes or injuries related to this issue for the US market.

 

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 Powersports dealer. The dealer will visually inspect the lot number on the ABS modulator and replace affected ABS modulators 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.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
HONDA CB500X 2019-2020
HONDA CBR500R 2019-2020

 


10 Associated Documents

Defect Notice 573 Report

RCLRPT-21V690-7661.PDF 215.96KB

RCLRPT-21V690-7661

 


Miscellaneous Document – Part 573 – Defect Information Report 2019-2020 Model Year Honda CB500X and CBR500R ABSABS Modulator

RMISC-21V690-3726.pdf 116.537KB

RMISC-21V690-3726

 


Recall Acknowledgement

RCAK-21V690-4573.pdf 745.344KB

RCAK-21V690-4573

 


Manufacturer Notices(to Dealers,etc) – 2019-2020 CB/CBR500 #1 Service Bulletin

RCMN-21V690-6828.pdf 42.562KB

RCMN-21V690-6828

 


Manufacturer Notices(to Dealers,etc) – STOP SALE NOTICE: 2019-2020 CB500XA/CBR500RA ABS MODULATOR INSPECTION RECALL

RCMN-21V690-8179.pdf 53.414KB

RCMN-21V690-8179

 


Recall 573 Report – AMENDMENT 1

RCLRPT-21V690-9316.PDF 215.96KB

RCLRPT-21V690-9316

 


Recall Quarterly Report #1, 2021-4

RCLQRT-21V690-7327.PDF 211.142KB

RCLQRT-21V690-7327

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V690-9635.pdf 137.348KB

RCONL-21V690-9635

 


Remedy Instructions and TSB

RCRIT-21V690-6925.pdf 746.856KB

RCRIT-21V690-6925

 


Recall Quarterly Report #2, 2022-1

RCLQRT-21V690-0665.PDF 211.24KB

RCLQRT-21V690-0665

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V690&docType=RCL

 


 

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