havabusa12r
Expert Class
Posts: 425
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posted December 20, 2002 05:43 PM
'02 RECALL NOTICES???
As I was setting up my tire appointment, I mentioned that I was about ready for the 7500 mile service.
The service mgr asked if I got my recall letter?
Of course, I have not yet received anything.
It is for the well known zx12 board issue of the rectifier
connection harness. I had forgotten all about it.
He also informed me that they had not received the repair parts......
Are there any other recalls or service bulletins out there?
____________
(68 Yam 175 2-stroke)
(99 Copper Busa) (99 Duc 900 SS full fairing) (00 MV Agusta F4S) (02 Aprilia RSV Mille) (02 ZX 12r CTB) (03 KTM 950 Adv)
(04 Yam R1) (05 LE Busa) (07 ZX 14)
  
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blubyu
Expert Class
Posts: 209
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posted December 20, 2002 05:45 PM
recall notice
Never heard anything about a recall notice. That's news to me.
____________
Run whatcha brung
Tow whatcha blow
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havabusa12r
Expert Class
Posts: 425
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posted December 20, 2002 05:48 PM
quote:
Never heard anything about a recall notice. That's news to me.
I know that we are usually way AHEAD of most dealers because of these boards. They seem not to know or believe
us? I was suprised-maybe the recall just came out?
____________
(68 Yam 175 2-stroke)
(99 Copper Busa) (99 Duc 900 SS full fairing) (00 MV Agusta F4S) (02 Aprilia RSV Mille) (02 ZX 12r CTB) (03 KTM 950 Adv)
(04 Yam R1) (05 LE Busa) (07 ZX 14)
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geoffwood
Novice Class
Posts: 32
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posted December 20, 2002 08:08 PM
I did some digging on the NHTSA site. Didn't find any new recalls, but I did find out that my cracked winglets are covered under a TSB 
Winglet TSB
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redelk
Moderator
Please... speak to the hand.
Posts: 3212
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posted December 20, 2002 11:34 PM
I had the plug that connects the stator to the rectifier fry on mine. Oops! Sorry! Mine was a 2000 A-1 model. Not to mention that it happened after 37K+ miles.
The only problem I have ever heard about wire harnesses attached to the rectifier is oil migrating up the harness from the stator. I've also never heard of it causing any type of electrical short in the harness , connecting plugs or rectifier. This too, seemed to only apply to A1 and A2 models. No one, that I know of has had either of these problems with B1 or B2 models.
If they actually do a recall requiring the harness between the stator and rectifier be replaced, all I can say is I hope the have fun doing it. There is another harness connected to the rectifier, but I doubt that's the one they might be referring to.
If it is the stator harness, I could easily see the labor book saying it's a 3.5 hour job. Like many other hourly "estimations", this is woefully low. The harness does not plug in to the stator... it's hard wired to stator coil (part # 21003-1391 on the '02 B1). It could also require the replacement of the rectifier (voltage regulator part # 21066-1119 on the '02 B1), if it's an "connection" issue.
While the replacement of the rectifier is a breeze, the replacement of the stator is not. It's not really the installation of the stator that is the problem. it's the routing of the stator's harness to the rectifier, that such a pain in the ass. One of the fuel lines and the crankcase breather hose has to be removed. Even after doing that, it would almost be easier to lower the rear of the engine so you can route the plug itself trough the frame.
Not to mention that this would be one of the most expensive recalls on any 12R. Just replacing the stator, including the labor, could go well over $350 to $400 (if not possibly more!). The funny part is that even with a fried plug, my bike ran fine until I actually had the seperate the plugs connecting the stator and the rectifier. Not only were the plugs melted together, but the wires going into the stator's plug were fried too.
If you ever wanted to get in good with your dealer, now would be the time to offer to do the labor yourself. Not only will the dealer be able to pocket a little extra change (the labor costs), his mechanic will still speak to you the next time you come in. Force them to do it and the mechanic will never want to work on your bike again. I promise you.
____________
There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely games.
-Ernest Hemingway
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ZHooligan
Moderator
Post Whore Extraordinaire!
Posts: 3829
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posted December 21, 2002 01:14 AM
After replacing the stator yourself you might decide to give up working on your bike as well! I used to cut them (the dealer) slack and do the work for them. Not anymore. I paid for a new bike, I paid for a warranty so they can fix it. And as is pretty typical in both the auto and motorcycle industry the dealer can be creative and come up with some additional Waranty work to make some money!
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redelk
Moderator
Please... speak to the hand.
Posts: 3212
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posted December 21, 2002 02:02 AM
Z, in most cases and for most folks, I'd have to agree with you.
It's just that all the other "bennies" I get from my dealer for doing such, FAR OUTWEIGH these rare opportunities (at least I hope they are) for him to pocket a little warranty labor costs. If it starts to even get close to 5% of the value of what he's saved me in bikes, parts, service and accessories... I might reconsider.
Until then, I'll be more then happy to scrap my knuckles instead.
____________
There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely games.
-Ernest Hemingway
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ZHooligan
Moderator
Post Whore Extraordinaire!
Posts: 3829
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posted December 21, 2002 08:37 AM
I understand what you saying elk. I work with the dealer to make sure he is taken care of. The relationship must work so far as I am about to build his new facilities. In my case the little niggly things I tale care of and let them bill the waranty work. But when it comes to thenasty jobs I let them handle it!
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atmcore
Parking Attendant
Posts: 2
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posted December 23, 2002 11:01 PM
My letter says:
ZX-12R OIL SEEPAGE FROM ALTERNATOR LEAD CONNECTOR
It is for all models 2000-2003 zx1200-A1/L, ZX1200-A2/L, ZX1200-B1/L and ZX1200-B2/L.
Safety issue because of possibility of oil leaking on rear tire causing accident.
Correction will consist of sealing the alternator lead wires. This repair will take about one half hour for the dealer to complete. The parts to complete this repair will be available to dealers the fourth week of December.
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beansbaxter
Needs a life
Posts: 5911
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posted December 23, 2002 11:58 PM
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TedG
Moderator
Posts: 8222
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posted December 24, 2002 11:26 AM
Geeze Red throw away those craftsman tools, I not only removed the stator and harness, I made crimp-clamps for the wire, shrink tubed each if the crimped wires, but replaced the whole thing while they ordered me a new one, in about an hour. Then when I got the new one I did that in 15 minutes. Took me longer to drive to the shop to get the part.
____________
Ted
2000 Green ZX12 sold
The fast color!!
Green 2005 ZX10R
2009 Concours Black ABS
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redelk
Moderator
Please... speak to the hand.
Posts: 3212
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posted December 24, 2002 12:11 PM
ARRRRRRRRGH, Ted! It's not ALL TOOLS, ya know? A little bit has to do with "mechanical skills". Okay... OKAY! It does have a lot to do with "tools" and I have neither the "tools" or the "skills"!
ARRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRGH!
____________
There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely games.
-Ernest Hemingway
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beansbaxter
Needs a life
Posts: 5911
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posted December 24, 2002 12:14 PM
redelk....dont get frustrated, use a smile face to convey your holiday emotions.
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your car is slow
Needs a job
Fuck Nitrous...Got Boost?
Posts: 4089
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posted December 25, 2002 01:06 AM
Fixed mine with about 1/4 tube of RTV...but nice to know there is a recall.
____________
Do not taunt happy fun ball!
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beansbaxter
Needs a life
Posts: 5911
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posted December 25, 2002 06:23 AM
 Edited By: beansbaxter on 25 Dec 2002 06:23
I got my letter too today wooohoooo. Kawi hasnt forgotten about me!
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beansbaxter
Needs a life
Posts: 5911
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posted December 25, 2002 12:51 PM
Give peace a chance. 
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Hells Dark Lord
Needs a life
living life, and loving it.
Posts: 7981
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posted December 28, 2002 08:12 AM
will have to give my dealer a call and inquire about this.....thanks for the heads up.....Jim
____________
When in doubt, lean farther and go faster....
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BA
Pro
Posts: 1592
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posted December 28, 2002 09:27 PM
Got my letter today too!
Damn good job of all the riders who chipped in their two cents here and at other sites. There may not be a recall solely because of us all, but I'd like to think that it helped!! 
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redelk
Moderator
Please... speak to the hand.
Posts: 3212
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posted December 28, 2002 11:06 PM
I just made a copy of my dealer's SIX PAGE "instruction" sheet (Bulletin MC 02-11) that came with the "Official KHI Recall Repair Kit". What a hoot! There are SIXTEEN pictures and FOUR diagrams.
They are instructed to "Replace the harness clamp if the harness clamp is soaked with engine oil" (PN 92171-1255). They are also instructed to make a small punch mark on the frame directly above the top rivet holding the ID plate, indicating that the recall service has been done.
The kit consists of a large bottle of "crazy glue" (supposedly enough to do 20 bikes), a roll of electrical tape (more than enough fro 20 bikes) and a small flat blade jeweler's screwdriver (to get the wires out of the plug). Oops! Sorry, it's called a "Terminal Removing Tool".
In a nutshell, here's what is supposed to be done...
1. Remove rear seat, front seat and side panel.
2. Disconnect the alternator lead connector.
3. Remove the vinyl (black) tape from the harness, approximatly 100mm from the connector.
4. Remove the plastic lead tube (so THAT's what they call that plastic wire cover!)
5. Remove vinyl tape that covers intermediate connection (where the two wires go into one before the plug)
6. Remove terminals from the plug.
7. Clean terminals with contact cleaner (SEVEN steps and must be repeated THREE times!)
8. Apply "quick curing adhesive" where the wire is crimped to the terminal to seal the wire (FIVE steps!).
9. Apply adhesive to the top and bottom of the intermediate connection (Three steps!)
10. Insert terminals into plug (the same position they were in).
11. Wind 4 to 5 turns of tape around the intermediate connnection.
12. Put plastic tube over wires.
13. Wind tape 2 to 3 times around the end of the tube (by the plug) and continue to wrap the tube until you overlap the original tape wrap (approx. 100 mm).
14. Clean the regulator connector and the area around the connector with contact cleaner.
15. Reinstall the removed parts in reverse order.
16. Make "Repair Verification" mark on frame.
17. Fill out "Warranty Claim" documentation (REQUIRED by Federal Law - NHTSA Law 49 U.S.C. Section 30210(i) or they will keep sending the customers notices).
Repair time: 0.5 hour.
Other Recalls and/or Bulletins
MC 00-02 - Break-in mileage change (guessing)
MC 00-04 - Proper spacing of front wheel (service bulletin/manual addendum)
MC 00-06 - (don't know)
MC 00-07 - Cracked winglets (service bulletin)
MC 00-08 - Proper clutch release lubrication procedures (service bulletin/manual addendum)
MC 00-09 - (don't know)
MC 00-13 - Fuel tank leak and fuel gauge (NTSHA recall)
MC 01-07 - Wheel valve stem locking nut (NTSHA recall)
MC 02-11 - Oil seepage from alterator lead connector (NTSHA recall)
____________
There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely games.
-Ernest Hemingway
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beansbaxter
Needs a life
Posts: 5911
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posted December 29, 2002 03:17 AM
Should I fix my 02 model, or wait for it to break?
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