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21. Suzuki GSXR600
With approaching twice as many bikes involved as the next biggest recall, we have a runaway winner here. The problem itself was also the reason it involved so many machines; it involved a brake master cylinder that could corrode over a period of time after water had been absorbed by the brake fluid. The corrosion itself wasnt even a big problem, but the gas created during the corroding process stayed in the brake system, making for a spongey lever and possibly reduced braking force. Given the complex and lengthy process leading to the problem, its understandable that it wasnt spotted during development; its the sort of flaw that takes years of realworld use and abuse to emerge. The fix was a new master cylinder for all 29,422 bikes.
22. Triumph TT600
This multibike recall was down to a risk that plastic fuel pipe connectors on the fuel pump mounting plate could break, leading to a fuel leak. The fix was a redesigned part made of metal instead of plastic ? simple, but effective.
23. Suzuki DL100
Its one of those pesky electrical issues again, this time a regulator/rectifier used across a massive range of Suzukis. It could fail, leading to a flat battery that might, in extreme circumstances, lead to the engine stalling. The fix was simple; replace the regulator/rectifier unit with a good one.
24. Yamaha YZFR1 and YZFR6
Funnily enough the problem here was virtually identical to the issue that hit the YZFR125 a dozen years later (in 10th on this list). The sidestand switch bolt could come loose or fall out, making the switch inoperative and allowing the bike to be ridden even if the stand was still down. A new set of nuts and bolts solved the issue, so at least it was a cheap fix for Yamaha, even though it was spread over nearly 15,000 bikes.
25. Yamaha YZFR1
Electrical components are commonly shared between multiple models, which explains how the same recall can hit bikes as disparate as the Yamaha R1 and the XT660R. The issue here was a dodgy throttle position sensor, which led to some bikes having an unstable idle speed or even stalling. The recalls simply involved checking whether the bad part was fitted and replacing it with a good one.
26. Honda VFR800
Can you spot the component that connects the VFR800, Pan European, Blackbird, Varadero and Goldwing? Yup, its the CBS linked braking system, which in this recall was found to be prone to leaking fluid due to a manufacturing fault in some proportional control valves used on the bikes. The fix was simply to check the bikes and replace the dodgy parts with ones manufactured to the correct specification.
27. BMW K1200RS
It seems that 2005 was a bad year for big recalls. This one hit multiple BMW models because it was due to a problem with the quickrelease fuel coupling between the tank and the rest of the fuel system ? a part used on most of the firms range. Bikes got new Orings in the coupling, and a complete replacement part in some cases.
28. Honda CBR125R
Another 2005 issue hitting multiple models, this time it was a problem with water getting into the ignition coil and corroding it. For most, that meant the bikes were hard to start, but it could also lead to engines cutting out. Unsurprisingly, the fix was a revised coil.
29. Yamaha XV125
Its not unusual for recalls to hit multiple models, particularly when they share a common component. In this case, that part was a bolt that helped hold the pillion seat in place, which could work loose; clearly bad news for your passenger. A redesigned attachment was created to fix the problem and these days it would be a surprise to find a bike with the original part still in place.
30. Yamaha YZFR125
With so many R125s on the road, its no surprise to see it on this list. The 2012 recall came after it was found that the sidestand switch could work loose, in extreme circumstances allowing the bike to be ridden with the sidestand down. A replacement mounting bolt kit sorted the problem.
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