2020 Honda CRF1100D4

Closed preliminary evaluation · opened August 10, 2020 · closed January 15, 2021 · led to recall 20V797000

the gasoline fuel system, the fuel system

The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) on August 10th, 2020 to investigate 26 reports of stalling due to clogged fuel filters on model year (MY) 2018 - 2020 Honda African Twin (CRF 1000 - 1100) motorcycles.Many of the owners allege the subject vehicle would suddenly stall while riding. Although the stalling speeds varied, most consumers allege the stalling occurred at highway speeds. This stalling condition is caused by clogged fuel filters. The subject vehicle fuel filters become contaminated with zinc-oxide (corrosion). The corrosion is coming from the inside of the fuel tank, along the end seam of a joint weld. The corrosion clogs the fuel filter, restricts fuel flow to the engine, and subsequently causes a sudden engine stall.During complainant interviews, ODI learned the bikes can sometimes be restarted after the initial stall. However, several consumers described this restart as causing a false sense of security.After restarting the bike and attempting to accelerate/merge into traffic, the bike quickly stalls again. This time the rider is placed in the middle of traffic, potentially causing a crash or risk of injury.On October 9, 2020, ODI received Honda?s Information Request (IR) response and learned that Honda was aware of 36 complaints, 87 field reports and 83 warranty claims of stalling related to clogged fuel filters. There were no claims of crashes or property damage associated with the alleged defect on the subject motorcycles. Additionally, Honda initiated three different modifications or changes to the fuel tank during production. On March 11, 2020, Honda released a customer satisfaction campaign to remove the zinc oxide that can contaminate the fuel pump filter, causing reduction of fuel flow. The part numbers for the fuel tank did not change after the implementation of the zinc oxide removal process. The process improvement was a running-change and no parts were withdrawn from production. On October 5, 2020 Honda added a new maximum contamination specification. This new specification was initiated to limit the contamination from the tank supplier. The tank supplier improved the cleaning process to meet the low contamination limit.Discussions and analysis of the data between ODI and Honda resulted in the manufacturer recalling certain 2018-2019 Africa Twin Adventure Sports (CRF1000L) and 2020 Africa Twin Adventure Sports (CRF1100L) motorcycles.Contaminants inside the fuel tank may cause the fuel filter to clog, resulting in an engine stall, and increasing the risk of a crash.ODI is closing this PE with Honda?s voluntary safety recall 20V-797. With the recall action taken by Honda, this investigation is closed, as further use of agency resources does not appear to be warranted.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist on other models or MY vehicles outside of the recall scope. The agency reserves the right to take further action if warranted by the circumstances.

crash · towed · 3,200 miles

WHEN GARAGING, I HAVE TO ROLL BACK AND MOVE FORWARD TO SQUARE OFF. BEING AN AUTOMATIC, YOU HIT A SWITCH TO CHANGE N TO D. I HIT N, ROLLED BACK, HIT D AND RELEASED THE BRAKE. THE BIKE SHOT FORWARD WITH NO THROTTLE INPUT 10 - 15 FT HITTING A ROCK WALL AND THROWING ME AGAINST MY CAR PINNING ME. NO ONE HEARD ME HOLLER FOR HELP. I HELD THE BRAKE WHILE REACHING OVER WITH MY LEFT HAND AND HIT THE KILL SWITCH BEFORE HEAVING THE BIKE OFF ME. I WAS REALLY SHAKEN UP. THE INSURANCE CO. TOTALED THE BIKE. IT HAD HAPPENED TO MY WIFE TOO A MONTH AFTER GETTING THE BIKE. LUCKILY SHE WAS IN AN OPEN AREA. IT HAS HAPPENED TO OTHERS AS INDICATED ON THE HONDA AFRICA TWIN FORUM.

NHTSA complaint 11389349. Filed by an owner and not verified by NHTSA or by us.

The CRF1100 2020 DCT stalls when trying to take off form a complete stop. It happens most often at traffic lights and has already lead to dangerous situations with cars behind you expecting you to go but you stall. This bike is not supposed to stall and since it only happens on occasion (so far perhaps around 20 times), yesterday's ride it happened 3 times. It is hard to rely on the bike behaving as you would expect. There are many others on forums talking about this and there was a recall in 2020 but my bikes VIN was not on the recall list. I wonder if they scoped the recall too narrow as my bike seems to have that exact issue.

NHTSA complaint 11757441. Filed by an owner and not verified by NHTSA or by us.

180 miles

ON MULTIPLE OCCASIONS, THE ENGINE CUT OUT. SEVERAL TIMES WHILE I OPEN THE THROTTLE ALL THE WAY QUICKLY TO PASS ON A TWO LANE HIGHWAY. SEVERAL TIMES WHEN I'M CRUISING DOWN THE HIGHWAY AT 70 MPH, IT JUST STARTED MISSING. VERY DANGEROUS WHEN YOUR SPEED GOES FROM 70 TO 40 IN SECONDS ON THE FREEWAY.

NHTSA complaint 11376833. Filed by an owner and not verified by NHTSA or by us.

4,000 miles

VEHICLE WAS IN MOTION ON AN INTERSTATE HIGHWAY AT APPROXIMATELY 70 MILES AN HOUR, IN TRAFFIC, WHEN ENGINE SUDDENLY STOPPED RECEIVING ADEQUATE FUEL. REVS WERE LIMITED TO 4K AND INCOMING TRAFFIC BEHIND ME NEARLY CAUSED A COLLISION, DUE TO MY SUDDEN LOSS OF SPEED WITHOUT BRAKE LIGHTS. UPON TAKING TO SHOP, A WHITE PASTE-LIKE SUBSTANCE WAS FOUND COVERING SOME OF THE KEY WELDS INSIDE THE GAS TANK. THIS SUBSTANCE FLAKES OFF AND CLOGS THE FUEL FILTER. IN MY CASE, THIS HAPPENED WITHIN THE FIRST 4,000 MILES. THIS APPEARS TO BE A MANUFACTURING ERROR IN WHICH THE HEAT OF WELDING CAUSES A SPECIAL GAS TANK LINING TO CORRODE AND FLAKE OFF. UNLESS PROACTIVE MEASURES ARE TAKEN BY THE CUSTOMER BEFOREHAND - …

NHTSA complaint 11352076, quoted in part. Filed by an owner and not verified by NHTSA or by us.

425 miles

IMPROPER FUEL TANK WELDS PLUGGED THE FUEL FILTER WITH DEBRIS. DISCOVERED THE ZINC FLAKES UPON INSPECTION OF THE FUEL TANK. 425 MILES ON THE MOTORCYCLE AND LESS THAN 10 GALLONS OF GAS THROUGH THE TANK. UNLIKE AUTOMOBILES, WHEN A MOTORCYCLE FUEL SYSTEM IS COMPROMISED, A LOSS OF POWER CAN BE CATASTROPHIC TO THE RIDER. UNWILLING TO RISK MY SAFETY, INCLUDING DEATH, I WAS PROACTIVE IN MY INVESTIGATION OF THIS OWNER AND DEALER KNOWN ISSUE, AND STARTED MY OWN MAINTENANCE PLAN TO PREVENT AN UNINTENTIONAL DANGEROUS LOSS OF POWER, WHICH MIGHT OCCUR ON THE INTERSTATE HIGHWAY SYSTEM AT 70 MPH. SEE ATTACHED PHOTOS OF A NEW HONDA MOTORCYCLE FUEL SYSTEM.

NHTSA complaint 11352086. Filed by an owner and not verified by NHTSA or by us.

2,500 miles

THERE IS A CORROSION OR SOME OTHER TYPE OF DETERIORATION OF THE FUEL TANK WELDS INSIDE THE TANK THAT CAUSE A PARTICLE BUILD UP THAT CLOGS THE FUEL PUMP AND CAUSES THE VEHICLE TO LOSE POWER AND STALL. THE POWER LOSS HAPPENS PERIODICALLY. HONDA HAS FLUSHED THE FUEL TANK AND REPLACED THE FUEL PUMP HOWEVER THE PARTICLES IN THE FUEL TANK ARE STILL PRESENT. PICTURES ARE OF BEFORE HONDA FLUSHING TANK AND AFTER.

NHTSA complaint 11343794. Filed by an owner and not verified by NHTSA or by us.