2019 Honda CRF450L Horn Stay Broken

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October 3, 2019 NHTSA CAMPAIGN NUMBER: 19V703000

Horn may Detach from Motorcycle

An unsecured horn may interfere with the motorcycle while driving, affecting handling and control, or it may fall off and become a road hazard. Either of these scenarios can increase the risk of a crash.

 

NHTSA Campaign Number: 19V703

Manufacturer Honda (American Honda Motor Co.)

Components COMMUNICATIONS

Potential Number of Units Affected 4,348

 

Summary

Honda (American Honda Motor Co.) is recalling certain 2019 CRF450L motorcycles. The horn mount may break, allowing the horn to detach from the motorcycle.

 

Remedy

Honda will notify owners, and dealers will replace the horn and horn mount, free of charge. The recall began November 2019. Owners may contact Honda customer service at 1-866-784-1870. Honda’s number for this recall is KK4.

 

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

 


CRF450L #1
REVISED: October 18, 2019

 

SAFETY RECALL

This bulletin replaces CRF450L #1, issued October 2019

2019 CRF450L HORN STAY BROKEN

 

BACKGROUND

Honda is launching a SAFETY RECALL on ALL 2019 CRF450L motorcycles to replace the horn assembly. Under certain conditions, the horn stay can break causing the horn to become loose or fall off.

Honda will provide an improved horn assembly to replace the defective part.

This Service Bulletin includes the recall repair procedure to replace the horn assembly, along with parts and warranty information.

Honda will notify customers via letter by December 2019, advising to make an appointment with an authorized Honda dealer to perform the recall repair by replacing the horn assembly with the improved part.

 

AFFECTED UNITS

MODEL VIN RANGE
2019 CRF450L ALL

 

DEALER INVENTORY

Effective September 30, 2019, YOU MUST NOT SELL any NEW OR USED 2019 CRF450L motorcycle 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, you must use eResponsibility Report on iN.

 

PARTS INFORMATION

Parts are available through the normal parts ordering process.

DESCRIPTION P/N QTY.
SET, Horn 06380-MKE-306 1

 

TEMPLATE CLAIM INFORMATION

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

MODEL TEMPLATE FLAT RATE
CRF450L KK4A 0.4

 

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 remedyto 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.

 

WARRANTY QUESTIONS

If you have any warranty administration questions relating to template claims and claim filing procedures, please contact: Motorcycle Warranty Online:

iN > Service > Warranty & HondaCare > Warranty Connect

Or call (800) 421-1900, option 7.

 

TECHNICAL QUESTIONS

If you have any technical questions relating to the repair procedure, please contact: Motorcycle TechLine Online:

iN > Service > TechLine > TechLine Connect

Or call (800) 421-1900, option 9.

 

RECALL REPAIR IDENTIFICATION

Before performing the recall repair, inspect the motorcycle’s horn assembly to determine if the repair has already been per- formed.

  • If the remedy horn assembly (shown below) is currently installed, the recall repair has already been No repair is needed.
  • If the original horn assembly (shown below) is currently installed, the repair needs to be Continue to the Recall Repair Procedure section.

 

RECALL REPAIR PROCEDURE

Refer to page 20-23 in the 2019 CRF450L Ser- vice Manual to perform the recall repair by replacing the original horn assembly with the remedy horn assembly.

NOTE: There are two new clips for the horn harness included in the remedy parts kit. Use these clips to replace the original clips, if dam- aged.

 


November 2019

NHTSA Recall 19V-703

IMPORTANT SAFETY RECALL

This notice applies to your vehicle: XXXXXXXXXXXXXXXXX

Dear Honda Powersports Customer:

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

 

WHAT IS THE REASON FOR THIS NOTICE?

Honda has determined that a defect which relates to motor vehicle safety exists in all 2019 CRF450L motorcycles. The horn stay was insufficiently designed to tolerate motor resonance. The horn stay can break and the horn can become unsecured. An unsecured horn can interfere with the motorcycle or fall into traffic, increasing the risk of a crash.

 

WHAT WILL HONDA DO?

The dealer will replace the horn and horn stay with a redesigned assembly free of charge.

 

WHAT SHOULD YOU DO?

Please call any authorized Honda motorcycle dealer and make an appointment to have the horn and horn stay replaced with a redesigned assembly free of charge. Once you schedule an appointment for your motorcycle, be advised that the replacement process may take approximately 30 minutes. However, your dealer can provide you with a better estimate of the overall time for this service visit, as it may be necessary to make your motorcycle available for a longer period of time. If you are not the only rider of this motorcycle, please advise all other riders and passengers of this important safety information.

For assistance locating a Honda motorcycle dealer, you may call Honda Powersports Customer Service at:   (866) 784-1870 or use the “find a dealer” option on www.powersports.honda.com.

 

CHECK YOUR MOTORCYCLE FOR OPEN RECALLS

You can check your motorcycle’s eligibility for repair under this or any other recall. Please access the Honda recall lookup tool at www.powersports.honda.com/recalls.aspx and enter your VIN.

 

OWNER INFORMATION

You received this recall notice because government regulations require that notification be sent to the last known owner of record. Our records are based primarily on state registration and title data, which indicate that you are the current owner of this motorcycle. If this is not the case, or if any of the information is incorrect, please complete, sign and return the Information Change Card and we will update our records. If you are a lessor of this motorcycle, Federal Regulations require you to forward this notice to your lessee within ten days.

 

DO YOU STILL HAVE MORE QUESTIONS?

Should you have any questions about this recall, please contact your authorized Honda motorcycle dealer. Should you need additional assistance, you may contact Honda Powersports Customer Service toll free at (866) 784-1870.

If you believe that American Honda or the dealer has failed or is unable to remedy the defect in your motorcycle free of charge, within a reasonable period of time (within 60 days from the date you first contacted the dealer for a repair appointment), you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE, Washington, DC 20590.

Alternatively, you may call the NHTSA’s toll-free Safety Hotline at 888-327-4236 (TTY 800-424-9153), or go to: www.nhtsa.gov.

We apologize for any inconvenience this recall may cause you.

Sincerely,

American Honda Motor Co., Inc.

Powersports Products

Campaign #KK4 / Service Bulletin: CRF450L #1

 


CRF450L #1
ISSUED: SEPTEMBER 2019

SAFETY RECALL

2019 CRF450L HORN STAY BROKEN

Honda is launching a SAFETY RECALL on ALL 2019 CRF450L motorcycles to replace the horn assembly. Under certain conditions, the horn stay can break causing the horn to become loose or fall off.

Effective immediately, you MUST NOT SELL any affected NEW or USED 2019 CRF450L motorcycle until it is repaired according to the associated Service Bulletin.

 

AFFECTED UNITS

2019 CRF450L – ALL

To manage your affected inventory, use eResponsibility Report.

 

SERVICE BULLETIN

Service Bulletin CRF450L #1, which will include the repair procedure, parts information, and warranty claim information, will be posted early-October.

 

PARTS INFORMATION

Parts will be available on open order.

 

CUSTOMER NOTIFICATION

AHM intends to mail customer notification letters as early as possible, subject to regulatory agency approval.

Make sure all departments in your dealership are aware of this action.

Honda will update dealers with any new information as it becomes available.

If you have any questions, please contact TechLine or your District Service Manager.

 

MTB 17333 (1909)

 


DEFECT INFORMATION REPORT

 

573.6(c)(1)

Name of manufacturer:

Honda Motor Co., Ltd.

 

Manufacturer’s agent:

John Turley
American Honda Motor Co., Inc.
1919 Torrance Blvd.
Torrance, CA 90501-2746

 

573.6(c)(2)

Identification of potentially affected vehicles:

Make/Model Model Year Dates of Manufacture Number of Vehicles
Honda CRF450L 2019 06/19/2018 to 04/18/2019 4,348

 

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

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

 

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

All 2019 CRF450L motorcycles are included in the recall.

 

Identification of affected component:

Component: Stay, Horn
Part No.: 50155-MKE-A50
Country of Origin: Japan
Manufacturer: Aioi Seisakusho Co., Ltd.

 

573.6(c)(3)

Total number of potentially affected vehicles: 4,348

 

573.6(c)(4)

Percentage of affected vehicles that contain the defect: 100%

 

573.6(c)(5)

Defect description:

The horn stay was insufficiently designed to tolerate resonance from the motor. Over time, stress fractures can develop, causing the stay to break and the horn to become unsecured. An unsecured horn could either interfere with the motorcycle or fall into traffic, increasing the risk of a crash.

 

573.6(c)(6)

Chronology:

March to April 2019

Honda received the first report of a broken horn stay from the Japanese market and launched an investigation.

 

May to June 2019

Preliminary analysis suspected the horn stay was fatiguing from motor resonance. The design specifications for the horn stay were re-evaluated.

 

July 2019

Honda received the first report of a broken horn stay from the U.S. market. Additional parts analysis was conducted to determine the failure mode and if it was similar to previous reports in other markets.

 

September 2019

Honda confirmed the design for the horn stay was insufficient in tolerating motor resonance.

 

September 26, 2019

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

 

As of September 26, 2019, Honda has received one warranty claim, and no reports of injuries or crashes related to this issue.

 

 

573.6(c)(8)

Program for remedying the defect:

Registered owners of all affected motorcycles will be contacted by mail and asked to take their motorcycle to a Honda Powersports dealer. The dealer will replace the horn and horn stay with a redesigned assembly for free.

 

Because the new motorcycle limited warranty on all affected motorcycles would have provided a free repair for the problem addressed by this recall, without any payment by the owner, reimbursement for pre-notification repairs will not be offered.

 

The estimated date to start notification to dealers: September 30, 2019

The estimated date to start notifications to owners: December 2, 2019

 

573.6(c)(1O)

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.

 

 

573.6(c)(11)

Manufacturer’s campaign number: KK4

 

 


 


1 Affected Product

Vehicle

MAKE MODEL YEAR
HONDA CRF450L 2019

 


13 Associated Documents

Recall Quarterly Report #2, 2020-1

RCLQRT-19V703-9506.PDF 211.241KB

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Recall Quarterly Report #3, 2020-2

RCLQRT-19V703-6755.PDF 211.326KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V703-5653.pdf 183.978KB

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Defect Notice 573 Report

RCLRPT-19V703-2304.PDF 213.495KB

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Remedy Instructions and TSB

RCRIT-19V703-4723.pdf 42.542KB

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DEFECT INFORMATION REPORT

RMISC-19V703-5238.pdf 92.782KB

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Manufacturer Notices(to Dealers,etc) – September 30, 2019 Subject STOP SALE NOTICE: 2019 CRF450L – Horn Stay Broken Safety Recall

RCMN-19V703-9607.pdf 40.743KB

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Remedy Instructions and TSB

RCRIT-19V703-9385.pdf 362.341KB

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Manufacturer Notices(to Dealers,etc) – 10/08/2019 Subject 2019 CRF450L #1 Service Bulletin now available

RCMN-19V703-1440.pdf 37.747KB

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Recall Acknowledgement

RCAK-19V703-4952.pdf 244.12KB

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Recall Quarterly Report #1, 2019-4

RCLQRT-19V703-8101.PDF 211.141KB

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Remedy Instructions and TSB

RCRIT-19V703-1286.pdf 433.014KB

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Recall Quarterly Report #4, 2020-3

RCLQRT-19V703-6290.PDF 211.433KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V703&docType=RCL

 


 

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