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MOTORCYCLE / ATV DIVISION 4 - STROKE
ALT/LT BULLETIN NO. 86
DATE: 5/30/2006
SUBJECT: RECALL CAMPAIGN - FRAME WELDING/REPLACEMENT
AFFECTED UNITS: EARLY PRODUCTION LT-R450K6 QuadRacer ATVs
REFERENCE: LT-R450 SERVICE MANUAL (99500-44060-03E)
ATTACHMENTS: CUSTOMER LETTER
COMPLETE POST WITH PICS:
http://www.postnetlnc.com/LTR450/Recall.pdf
NOTICE:
[red]This notice is sent to you in accordance with the requirements of the Consumer Product Safety Act.
Suzuki Motor Corporation has decided that a defect which relates to product safety exists
in certain 2006 model year LT-R450K6 QuadRacer ATVs. In cooperation with the U.S.
Consumer Product Safety Commission, Suzuki Motor Corporation is conducting a
voluntary Safety Recall Campaign for these ATVs.[/red]
WHAT IS THE PROBLEM?
[red]Suzuki Motor Corporation has determined that certain 2006 model year QuadRacer ATVs
have a rear suspension cushion lever mounting bracket on the ATV frame that can break
under certain high-stress conditions. The rear suspension cushion lever, which connects
the rear shock absorber and the ATV swing arm, is bolted to this mounting bracket. It is
possible that very high stress from making jumps and landing with the rear brake applied
can impart forces to the suspension lever mounting bracket, in the area around the bracket
mounting hole, which can cause the mounting bracket to break apart. If the mounting
bracket breaks apart, the rider could lose control of the ATV, possibly resulting in injury
or death.
DO NOT DELIVER an affected ATV to a customer until you have completed, or verified
completion of, the inspection/repair procedures outlined in this bulletin.
It is American Suzuki policy that ALL vehicles affected by a safety recall campaign be corrected
prior to sale or lease to a customer. You must verify this on the Suzuki "Certificate of Vehicle
Pre-Delivery" form (99923-09823-006), which is to be completed for all new and used vehicle sales.[/red]
STOP DELIVERY OF AFFECTED [more]
LT-R450K6 QUADRACER ATVS IMMEDIATELY
SAFETY RECALL CAMPAIGN
LT-R450K6 QUADRACER ATVs
FRAME WELDING/REPLACEMENT
CAMPAIGN #2089
VERIFY THE UNIT REQUIRES MODIFICATION
Before performing the recall inspection/repair to a unit, verify that the repair needs to be
done. There are three ways to verify this. If the unit is in the affected VIN range, check
the repair status by checking the Vehicle History in the SCAT Service Menu. If the repair
needs to be performed to the ATV, you will see the message “CAMPAIGN NOT YET
PERFORMED” displayed and the frame will need to be welded or replaced. Look for a punch
mark before the VIN (see page 10 of this bulletin). A punch mark before the VIN indicates
that the campaign repair has been completed. Inspect the welds on the rear suspension
cushion lever mounting bracket. Refer to the inspection procedure starting on page 6 of
this bulletin.
UNITS STILL IN THE CRATE:
Suzuki requests that you modify all units in your inventory as soon as possible.
AFFECTED UNIT VIN RANGE:
* Indicates the check digit.
Frame Kit Part Number Dealer Cost
LT-R450K6 99103-11216 0.36
ORDERING PARTS FOR THE RECALL CAMPAIGN
Parts for the recall campaign will NOT be auto-shipped to your dealership. Following the
inspection procedures starting on page 6 of this bulletin, if you determine that the frame
needs to be replaced, use your normal parts ordering method and refer to the part number
below to order the frame kit. Specify the preferred shipping method.
What's In the Frame Kit?
See next page.
JSAAL41A*62100089 ~ JSAAL41A*62111626
WHAT YOUR DEALERSHIP WILL DO:
Your dealership will inspect the frame to determine if it needs to be welded or replaced.
If necessary, replace the frame assembly.
- 3/13 -
CUSTOMER NOTIFICATION LETTER:
On June 2, 2006 Suzuki will mail notification letters to the owners of affected ATVs for
whom we have information. The letter asks the customer to contact the dealer where they
purchased their ATV to set an appointment for the recall repair.
What's In the Frame Kit?
NOTE: Numbers 1-2 and 1-3 are already installed in the frame (1-1).
NO. Part Number Part Name QTY
1-1 41100-45G00-YBA Frame Assembly 1
1-2 51661-31G00 Bush, Steering Shaft lower 1
1-3 51662-31G00 Seal, Steering Shaft Dust 1
2 62668-27A00-A05 Bolt, RR Cushion Lever FR 1
3 09159-12056-A05 Nut, RR Cushion Lever FR 1
4 09407-14407 Clamp, Radiator Cushion 2
5 09407-17403 Clamp, Wiring Harness 1
6 18794-45G00 Label, Information (E33) 1
7 68372-19B72 Label, Certification (E33/E19) 1
8 68374-45G00 Label, Compliance (Canada only) 1
9 04111-2015A Cotter Pin (not shown) 1
10 04111-2020A Cotter Pin (not shown) 9
11 04111-3025A Cotter Pin (not shown) 2
12 04111-4035A Cotter Pin (not shown) 2
- 4/13-
WARRANTY CLAIM PROCESSING:
Submit a warranty claim for each recall campaign service immediately upon completion of the
repair. This campaign requires you to file a warranty claim using only ONE of the methods
described below.
SCAT Short Form Claim:
The option of filing a SCAT Short Form Claim will NOT be available for this campaign.
FRAME HAS BEEN WELDED:
SCAT Long Form Claim:
Enter your labor time as 2.5 hours. Enter the actual welding expenses as sublet labor. If the
actual welding expenses are going to exceed .00 You WILL need to contact TECHLINE for
an authorization number BEFORE welding the frame.
NOTE: Please retain a copy of the repair order with a copy of the welding charges in your service
department as your TSM or ASMC may request copies to verify the warranty claim.
RECALL CAMPAIGN - FRAME WELDED
SCAT Long Form Claim
GENERAL
CLAIM NUMBER: XXXXX,X (Dealer enters number)
ENTRY TYPE: Model, Frame or Control Sequence
(Dealer Chooses)
MODEL: LT-R450K6
FRAME: X6XXXXXXX
REPAIR DATE: Enter date of repair
MILEAGE: Enter mileage or hours on unit
CAMPAIGN: 2089
LABOR HOURS: 2.5hrs
SUZUKI AUTH. NUMBER: As approved by TECH-LINE
PARTS
REPLACEMENT PART NUMBER: NO PARTS REQUIRED
FAILURE DESCRIPTION
DESCRIPTION OF FAILURE: FRAME REPLACED PER SERVICE
BULLETIN ALT/LT #86
SUBLET
SUBLET AMOUNT: Actual welding time or as approved
by TECH-LINE
- 5/13 -
Please submit a Warranty Request Form immediately after service is performed. Do not hesitate
to contact TECH-LINE (800/756-3251) or your District Technical Service Manager for guidance
or assistance.
FRAME HAS BEEN REPLACED:
You WILL need to contact TECHLINE for an authorization number.
WARRANTY CLAIM PROCESSING continued:
RECALL CAMPAIGN - FRAME REPLACED
SCAT Long Form Claim
GENERAL
CLAIM NUMBER: XXXXX,X (Dealer enters number)
ENTRY TYPE: Model, Frame or Control Sequence
(Dealer Chooses)
MODEL: LT-R450K6
FRAME: X6XXXXXXX
REPAIR DATE: Enter date of repair
MILEAGE: Enter mileage or hours on unit
CAMPAIGN: 2089
LABOR HOURS: 8.0hrs
SUZUKI AUTH. NUMBER: XXXXXXXXXXX
PARTS
REPLACEMENT PART NUMBER: 99103-11216 QTY 1
FAILURE DESCRIPTION
DESCRIPTION OF FAILURE: FRAME REPLACED PER SERVICE
BULLETIN ALT/LT #86
SUBLET
SUBLET AMOUNT: As approved by TECH-LINE
PARTS RETENTION
Attach a warranty parts tag (99923-09822-003) to all replaced frames and retain them
for 120 days. Make the frames unusable and dispose of them after 120 days if you have
not been instructed to do otherwise by an ASMC representative.
- 6/13-
PREPARING THE ATV FOR WELDING:
1. Remove the battery (refer to the service
manual).
2. Remove the headlight and disconnect the
ECM and Regulator/Rectifier (refer to the
service manual).
��
Before welding the frame, remove all the fuel system components from the unit. Make sure
to work in a well-ventilated area.
FRAME INSPECTION:
1. Clean the underside of the ATV, especially in the area of the rear suspension cushion lever
mounting bracket.
2. Place the ATV on a work lift and raise the lift so you can easily inspect the rear suspension
cushion lever mounting brackets welds for cracks (Figures A&B).
3. The rear suspension cushion lever mounting bracket will need to be welded even if it is not
cracked. If a weld bead is cracked, use a feeler gauge as a guide to confirm that the crack
is no wider than 0.5mm (0.020in) as indicated in Figure B. Follow the steps in this bulletin
to prepare the ATV and to have the bracket welded by a certified welder.
4. If the rear suspension cushion lever mounting bracket is cracked or a weld bead is cracked
in excess of 0.5mm (0.020in) as described above and indicated in Figure B, contact
TECHLINE for an authorization number to replace the frame assembly. Refer to the service
manual and this bulletin to replace the frame assembly. If frame replacement is required,
transfer the original frame number (VIN) to the replacement frame using a permanent
marking method.
Figure A Figure B
ECM Regulator/
Rectifier
- 7/13 -
PREPARING THE ATV FOR WELDING continued:
3. Remove the seat and the fuel tank cover by
removing the gas cap and the retainers.
5. Disconnect the fuel hose retainers.
4. Refer to section 5 of the service manual and
remove the fuel tank.
NOTE: The front fender does not need to be
removed to remove the fuel tank.
- 8/13-
7. Remove the fuel pump mounting bolts
and remove the fuel pump.
PREPARING THE ATV FOR WELDING continued:
6. Disconnect the fuel pump coupler.
9. Remove the lower chain roller.
8. Remove the right and left mud guards
and reinforcements.
- 9/13 -
FRAME WELDING PROCEDURE:
1. Turn the ATV onto its side. Use a block
approximately 6 inches high under the end
of the handlebar to support the ATV.
Skid plate
Bolts
PREPARING THE ATV FOR WELDING continued:
10. Remove the skid plate and loosen the
suspension cushion lever bolt and the
lower shock bolt so they can be
removed later.
2. Remove the suspension cushion lever bolt
and the lower shock bolt and move the lever
out of the way.
3. Cover the parts at the rear of the ATV using a
flame-resistant welding blanket.
- 10/13-
FRAME WELDING PROCEDURE continued:
4. Remove the paint and prepare the area to be welded
and the area to be used for the welding machine
ground clamp.
Use a grinder to remove any cracked weld beads.
5. Using a MIG or TIG welder, weld the entire
circumference of the support washer as shown. Do
not allow the weld bead to exceed the height of
the flat machined surface of the support as indicated.
6. After the first bracket weld has cooled, temporarily reinstall the cushion lever and lower
shock mount bolts to rotate the ATV over to the other side.
7. Repeat steps 1 through 5 on the opposite side.
8. After the welds have cooled, clean and prepare the area for paint.
9. Paint the repaired area using locally procured paint. (Color-Rite 800-736-7980, color code YBA)
10. Reassemble the ATV in reverse order. Refer to the service manual for the proper torque
specifications.
11. When the campaign repair is completed, punch mark the frame in the area in front of the
Vehicle Identification Number as indicated below.
Punch mark → JSAAL41A*62100089
Machined surface
Weld bead
- 11/13 -
Customer Letter attached ��
AFFECTED DEPARTMENTS:
The following departments in your dealership should be notified of this information:
⌧ Management ⌧ Service ⌧ Warranty ⌧ Sales ⌧ Parts ⌧ Accessories
American Suzuki Motor Corporation
Technical Service Department
Motorcycle / ATV
IMPORTANT:
Successful completion of this safety recall campaign depends on your efforts. It is your
responsibility to repair any affected ATV within the VIN range at no cost to the customer for
recall service parts and labor. Incidental costs your customers may incur are not normally
covered. However, if you have a customer with special needs, contact your District Technical
Service Manager (800/756-3251) to discuss possible solutions.
CUSTOMER SATISFACTION:
We understand and apologize for any inconvenience this recall campaign may cause you or
your customers.
Thank you for your cooperation in conducting this very important campaign for your customers'
safety and satisfaction.
Only your conscientious action at the dealership level can lead to a successful campaign
conclusion. Please remind your staff to be sympathetic and sensitive to your customers'
feelings. Please extend Suzuki's apologies for any inconvenience this recall campaign may
cause them.
- 12/13-
CUSTOMER NOTIFICATION LETTER - Page One of Two
Continued ��
June 2, 2006
Dear Suzuki Owner,
This notice is sent to you in accordance with the requirements of the Consumer Product
Safety Act.
What is the reason for this notice?
Suzuki Motor Corporation has decided that a defect which relates to product safety exists
in certain 2006 model year LT-R450K6 QuadRacer ATVs. In cooperation with the U.S.
Consumer Product Safety Commission, Suzuki Motor Corporation is conducting a
voluntary Safety Recall Campaign for these ATVs.
What is the problem?
Suzuki Motor Corporation has determined that certain 2006 model year QuadRacer ATVs
have a rear suspension cushion lever mounting bracket on the ATV frame that can break
under certain high-stress conditions. The rear suspension cushion lever, which connects
the rear shock absorber and the ATV swing arm, is bolted to this mounting bracket. It is
possible that very high stress from making jumps and landing with the rear brake applied
can impart forces to the suspension lever mounting bracket, in the area around the bracket
mounting hole, which can cause the mounting bracket to break apart. If the mounting
bracket breaks apart, the rider could lose control of the ATV, possibly resulting in injury
or death.
What is Suzuki doing to solve the problem?
Your dealer will inspect the frame to determine if it needs to be welded or replaced. If
necessary, the dealer will replace the frame assembly. There will be no charge to you for
any recall service related parts or labor.
AMERICAN SUZUKI MOTOR CORPORATION
SAFETY RECALL CAMPAIGN
LT-R450K6 QUADRACER ATVs
FRAME WELDING/REPLACEMENT
DO NOT OPERATE YOUR AFFECTED
2006 model year LT-R450K6 QuadRacer ATV
To minimize the risk of injury or death, do not ride, or allow anyone else to ride, your
ATV until your ATV has been repaired by your Suzuki dealer.
- 13/13 -
CUSTOMER NOTIFICATION LETTER - Page Two of Two
What to do if you receive this letter in error?
This notice was mailed to you according to the most current information we have available.
If you no longer own a 2006 model year LT-R450K6 QuadRacer ATV or never owned one,
please fill out and return the post card included with this letter. If you sold your ATV, please
forward this information to the person to whom you sold your ATV.
Who to contact if you experience problems?
Your Suzuki dealer can provide you the fastest response to your questions or concerns
about the frame program. If you have any difficulty with this recall campaign you may
contact the American Suzuki Customer Service Department for assistance using the direct
Customer Service telephone line at 714-572-1490. Please have your vehicle identification
number ready when calling. You may also leave a brief message at 800-444-5077 and
a representative from the American Suzuki Customer Service Department will get in
contact with you.
We deeply regret and apologize for any inconvenience this recall campaign causes you.
We earnestly hope you understand that your safety, satisfaction and riding pleasure are
priorities for Suzuki.
Sincerely,
American Suzuki Motor Corporation
What should you do?
Bring your ATV to your dealer for the repair. To aid your dealer and Suzuki, make sure
you are prepared for the recall service by taking the following steps:
√ Contact your Suzuki dealer as soon as possible to set an appointment for the
recall service
√ Plan your personal schedule so you will not miss your recall service appointment
√ When you transport your ATV to the dealership, take care to protect it from
damage and load it per the recommendations in the ATV's Owner's Manual
√ Clean your ATV thoroughly, so your dealer can perform the recall service quickly
http://www.postnetlnc.com/LTR450/Recall.pdf
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