2021 Honda Trail 125 (CT125A) Motorcycles KM8 Gearshift Pedal Replacement

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October 14, 2021 NHTSA CAMPAIGN NUMBER: 21V804000

Gearshift Pedal Arm Welded Improperly

A broken or detached gearshift pedal can increase the risk of a crash or injury.

 

NHTSA Campaign Number: 21V804

Manufacturer Honda (American Honda Motor Co.)

Components POWER TRAIN

Potential Number of Units Affected 2,181

 

Summary

Honda (American Honda Motor Co.) is recalling certain 2021 Trail 125 (CT125A) motorcycles. The gearshift pedal arm weld may fail, possibly resulting in the pedal breaking off the motorcycle.

 

Remedy

Dealers will replace the gearshift pedal assembly, free of charge. Owner notification letters were mailed December 10, 2021. Owners may contact Honda Powersports customer service at 1-866-784-1870. Honda’s number for this recall is KM8.

 

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

 


2021 Honda Trail 125
2021 Honda Trail 125

 


CT125A #1
October 2021

Service Bulletin

SAFETY RECALL

2021 CT125A – Gearshift Pedal Replacement

 

BACKGROUND

Honda is launching a SAFETY RECALL on CERTAIN 2021 CT125A vehicles to replace the gearshift pedal for a potential defect that may result in the failure of the gearshift pedal weld increasing the risk of a crash or injury.

 

AFFECTED UNITS

CERTAIN NEW or USED 2021 CT125A.

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 October 14, 2021, YOU MUST NOT SELL any affected NEW OR USED motorcycle in the AFFECTED UNIT section until it is 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, refer to eResponsibility Report on iN.

 

Customer Notification

American Honda intends to mail customer letters to all owners of affected 2021 CT125A vehicles in November 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 repair.

 

PARTS INFORMATION

Parts will be available starting November 1 2021, and can be ordered through the normal parts ordering process.

MODEL DESCRIPTION PART NUMBER QTY.
CT125A Set, Gear Change Pedal 06710-K2E-305 1

 

* Gearshift Pedal Set Includes:

Pedal Comp, Gear Change (Qty. 1), Rubber, Gear Change Pedal (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.

 

TEMPLATE CLAIM INFORMATION

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

MODEL RESULT TEMPLATE FLAT RATE
CT125A REPAIR KM8A 0.5

 

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 REPAIR PROCEDURE

Use protective tape on the right side step bracket to prevent damage to the engine covers.

 

Remove the four flange bolts [1] from the step bar [3].

Note:

  • This step is to allow clearance for the gearshift pedal removal.
  • It is not necessary to remove the flange bolts [2] for the cover pipe L/R

 

Remove gearshift pedal hex bolt [4] and gearshift pedal [5].

 

Install new gearshift pedal [5] onto the gearshift spindle [6].

 

Note:

  • Make sure grooves on the gearshift spindle and gearshift pedal align.

 

Note:

  • Make sure the gearshift pedal groove is perpendicular to the ground [7].

 

  • Ensure that the gearshift pedal hole aligns with the boss on the gearshift spindle.

 

Install new gearshift pedal hex bolt [4]. Tighten new bolt to 7 lbf·ft (10 N·m)

 

Install the four flange bolts [1] into the step bar [3]. Tighten the four bolts [1] to 16 lbf·ft (22 N·m).

 

Final Check: Be sure the gearshift pedal is installed at the correct angle.

 

TEXT OF CUSTOMER LETTER

Customer letter forthcoming.

 


Defect description:

Due to an inappropriate design of the gear shift pedal arm and insufficient weld strength between the gear shift boss and gear shift pedal arm, the weld may fail, and the gear shift pedal may potentially break off with repeated use, increasing the risk of a crash or injury.

 

Chronology:

February 21, 2021

A report was issued for the first occurrence in the Japanese market and an investigation ensued to identify if there were past occurrences which may have been related. Having found none, Honda decided to continue to monitor the issue in the market.

May 28, 2021

After additional occurrences in the Japanese market, Honda initiated an investigation at the manufacturing plant to analyze the issue further.

June 21, 2021

Parts returned from an occurrence were inspected and analyzed at the material level which indicated the gear shift pedal’s boss broke due to fatigue.

July 6, 2021

Production parts were tested and analyzed in an effort to determine the cause of the issue.

August 30, 2021

The tests and analysis of the production parts indicated that the weld point of the gear shift pedal arm to the gear shift pedal boss endures a high level of stress.

September 29, 2021

Honda conducted further analysis to determine the likelihood of the issue and the potential population of affected vehicles.

October 7, 2021

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

As of October 7, 2021, Honda has not received any warranty claims, field reports, nor reports of injuries, or crashes related to this issue for the US market.

 


Chronology :

February 21, 2021
A report was issued for the first occurrence in the Japanese market and an investigation ensued to identify if there were past occurrences which may have been related. Having found none, Honda decided to continue to monitor the issue in the market.

May 28, 2021
After additional occurrences in the Japanese market, Honda initiated an investigation at the manufacturing plant to analyze the issue further.

June 21, 2021
Parts returned from an occurrence were inspected and analyzed at the material level which indicated the gear shift pedal’s boss broke due to fatigue.

July 6, 2021
Production parts were tested and analyzed in an effort to determine the cause of the issue.

August 30, 2021
The tests and analysis of the production parts indicated that the weld point of the gear shift pedal arm to the gear shift pedal boss endures a high level of stress.

September 29, 2021
Honda conducted further analysis to determine the likelihood of the issue and the potential population of affected vehicles.

October 7, 2021
Honda determined that a defect related to motor vehicle safety existed and decided to conduct a safety recall.

As of October 7, 2021, Honda has not received any warranty claims, field reports, nor reports of injuries, or crashes related to this issue for the US market.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
HONDA CT125 2021

 


13 Associated Documents

Manufacturer Notices(to Dealers,etc) – 10/22/2021

RCMN-21V804-5083.pdf 42.107KB

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Manufacturer Notices(to Dealers,etc) – STOP SALE NOTICE: 2021 CT125A GERSHIFT PEDAL REPLACEMENT

RCMN-21V804-3119.pdf 32.829KB

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Recall Acknowledgement

RCAK-21V804-3828.pdf 698.22KB

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Remedy Instructions and TSB

RCRIT-21V804-1688.pdf 730.507KB

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Recall 573 Report – Amendment 1

RCLRPT-21V804-8885.PDF 214.011KB

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Recall 573 Report

RCLRPT-21V804-7194.pdf 214.484KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V804-9305.PDF 211.145KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V804-6941.pdf 137.734KB

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Manufacturer Notices(to Dealers,etc) – STOP SALE NOTICE: 2021 CT125A Gearshift Pedal Replacement

RCMN-21V804-8138.pdf 97.974KB

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Part 573 Defect Information Report – 2021 Model Year Honda Trail 125 (CT125A) Gear Shift Pedal Recall

RMISC-21V804-2009.pdf 86.753KB

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Recall Quarterly Report #2, 2022-1

RCLQRT-21V804-5568.PDF 211.247KB

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Recall Quarterly Report #3, 2022-2

RCLQRT-21V804-9379.PDF 211.333KB

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Recall Quarterly Report #4, 2022-3

RCLQRT-21V804-9790.PDF 211.439KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V804&docType=RCL

 


 

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