Suzuki Motors USA filed a vehicle safety recall with the US National Highway Traffic Safety Administration (NHTSA) for all 2022 through 2024 Hayabusas sold in this country. The issue is a faulty rubber part inside the front brake master cylinder, which "causes an inappropriate reaction to brake fluid."
I promise I'm not making this up; that's why I've quoted the recall document directly. And no, Suzuki didn't suddenly switch to a previously unknown, inexperienced brake component supplier. The part in question came from Hitachi Astemo, which is now the parent company of Nissin as of 2021.
As previously stated, this recall involves 100 percent of 2022 through 2024 Hayabusas sold in the US. By Suzuki's account, that's 6,338 total bikes. Affected production dates range from March 26, 2021 through March 29, 2024. Affected VINs range from JS1EJ11B5N7100001 to JS1EJ11B5N7100001, as well as a second range from JS1EJ11D3N7100001 to JS1EJ11D0R7100320. The affected VINs are non-sequential.
The specific problem, Suzuki says, relates to "certain elements in the brake fluid cap diaphragm" that could 'migrate' and cause a detrimental reaction between the brake fluid and rubber seal components within the front brake master cylinder. This reaction could cause the rubber to swell, which could in turn end up blocking the master cylinder primary port.
If this condition occurs, a rider could experience longer front brake lever travel. The bike could take longer to brake, and this could increase the risk of a crash.
Suzuki is acting to remedy this issue in two ways. One is the issuance of this safety recall, about which the company informed its dealer network on October 24, 2024 and sent notices to registered owners on October 25, 2024. Additionally, as of October 2024, the company is now using a revised brake fluid cap diaphragm, which it says is "constructed of material that will not react with brake fluid and cause seal cup swelling."
This recall is an expansion of this previous Suzuki Hayabusa recall issued in 2023. If you own a Hayabusa that already received service for that recall, Suzuki advises that you will still need to have this new 2024 recall service applied as well.
What does the recall service involve? Authorized Suzuki dealers will completely replace the front brake master cylinder body and its brake fluid cap diaphragm, free of charge to owners. Suzuki's campaign number for this recall is 3A04, and owners may contact Suzuki Customer Service at 1-714-572-1490.
Additionally, owners may contact the NHTSA Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153) or go to www.nhtsa.gov.
