brake-light-switch-recall-61-019-89-2342-489

Service-InformationM otorcycle BMW NA Service Department Group: 61 General Electrics April 1989 61 019 89 (2342) For USA Only Brake Light Switch Recall BMWo f North America, Inc. has voluntarily initiated a safety-related Recall Campaign. The NHTSA-assigned Recall Campaign number is 88V-192. This Service Information I outlines the specific procedure for implementation of this .Campaign. A copy of the customer notification is attached for your information. Vehicles Affected: Description of Defect: Cause: Al/ “R” ~es motorcycles from model year 1985 through 1988 and select 1989 motorcycles are involved. Pay special attention to the 1989 models, as only early producti on~torcycl es are affected. fl-:el ase note the affected VIN\range: Model VIN Range R65 6388193 – 6388255 6128001 – 6128516 R65LS 6371705 – 6371713 R80G/S 6363060 – 6363352 R80 6480001 – 6481120 R80RT 6490001 – 6491452 RlOOGS 6152004 – 6153373 RlOORS 6247001 – 6247599 RlOORT 6292601 – 6293397 The BMWm otorcycle contains separate front and rear brake light switches. The potential defect involves the contactina surfaces which activate these switches. Misalignment of either of these surfaces may cause that brake light switch to fail prematurely. If this should occur, the brake light would not function for that particular brake. Front Brake Light Switch The front Brake plastic pin, which near the area in lever. Light Switch incorporatPs a could bend due to a small ridge which the switch contacts the Rear Brake Light Switch The adjustable stop bolt which actuates the rear brake light switch may contact the plastic pin at an angle, causing the pin to form a ridge or bu~rr. ( Remedies: ( RemedyN o. 1: Note: ( RemedyN o. 2: The remedies are broken into three (3) groups, as described below. Please read each one carefully. 1. Inspect/replace front and rear Brake Light Switch 2. Modify front brake lever 3. Install a rubber cap on rear brake adjuster Visually inspect the front and rear Brake Light Switch to determine the co 1 or of the pin at the end of the switch. Switch (Part No. 61 31 1 459 519) with the White pin is the older type and must be replaced with switch (Part No. 61 31 1 459 569). Switches with a Black or Dark Gray plastic pin are the new type and need not be replaced. Some R80 G/Ss wi 11 use a different type Front Brake Light Switch. If the switch wires can be unp 1 uggPd from the switch end, then the switch is not the type being recalled. However, Remedy No. 2 should be performed. To inspect the front Brake Light Switch, remove the front brake lever and, using a flashlight, determine the color of the plastic pin. To inspect the rear Brake Light Switch, position a small mirror between the swing arm housing and right foot peg bracket. Press the brake 1 ever down to a 11 ow the plastic pin to come out of the switch. Using a flashlight, determinine the pin color. If either or rep 1 ace , the Replacement”. both switches have a White plastic pin, switch(es) see heading “Switch If you had previously replaced the switches, or the switches are the new type with a Black or Dark Gray plastic pin, operate the switch to ensure that it works properly. File the small ridge off the front brake lever, as described be 1 ow. This ridge may tend to force the plastic pin to one side, causing the pin to bind inside the switch housing. All affected motorcycles must have the ridge removed. ( Remedy No. 3: Replacing the Front Brake Light Switch: Caution: Replacing the Rear Brake Light Switch: Caution: I On all models except R80G/S and RlOOGS, a cap – Part No. 35 21 1 244 520 – must be fixed to the head of the bolt which operates the rear Brake Light Switch. Remove the fuel tank and protect it with the BMW Special Tool – 88 88 6 161 600 – or similar tank cover. Cut the three (3) cable ties that hold the switch wiring to the handlebar and wiring harness. Unplug the switch from the main wiring harness and, using an 11 l1’D11w rench, removed the switch from the right handlebar. Install the new switch – Part No. 61 31 l 459 569 – which has a Black or Dark Gray plastic pin. Cable-tie the switch wires as they originally were (part no. 61 13 l 372 531 or 61 13 1 243 092). Do not overtighten the switch. Use a drop of 242 blue Loctite on the threads and tighten the swiich to 3.6 ft/lb. Ensure that the switch works properly. Remove the rear wheel. Remove the right muffler. Remove the right battery side cover. Remove/release wing.nut on brake rod. Remove the upper shock mounting and carefully lower the rear drive/swing arm assembly until it stops, Cut the four (4) cable ties, holding the switch wires to the frame. Unplug the switch from the main wiring harness. Using an 11 mm and 13 mm wrench, loosen the nut holding the switch in place. Remove the switch. Loosen the adjustable stop light switch stop bolt and turn it in approximately 3.5 mm. Install the cap – Part Mo. 35 21 1 244 520 – on the head of the adjustable stop bolt. Install the new switch – Part No. 61 31 l 459 569 and cable-tie the wires to the frame·. Do not overtighten the switch. ( ( ( Brake Lever Modification: S.I. 2342 – page 4 Ensure that the Brake Light Switch is working properly. Install the upper shock mounting nut and torque to 21.2 ft/lb. Install the rear wheel assembly. Before torqueing the rear wheel lug bolts, have a co-worker hold the rear brake pedal down to center the brake drum. While the brake pedal is pressed down, torque the lug bolts to 77 ft/lb, Remove the sharp ridge with a file or belt sander. File or Belt-Sand Parts: Warranty Claim: R65; R65LS. R80, RBORT, Rl OORS; Rl OORT: Not every motorcycle will need new switches. Beginning with model year 1987, the new switch was installed during production. All affected motorcycles will need to have the brake lever modified and the rubber cap installed: Brake Light Switch – Part No. 67 31 1 459 569 Rubber Cap – Part No. 35 21 244 520 Reimbursement for this Recall Campaign will be provided through Campaign Claim submission. Please read Section 7 of the Motorcycle Warranty Manual for complete information about these special claims. Work Package #1. which includes: Modifying the front brake lever Installing a rubber cap Adjusting the rear stop light switch Defect Code: 00 00 61 04 00 Flat Rate Units: 8 (40 minutes) Part No. 35 21 l 244 520 RB0G/S and Rl 00GS: Work Package #2, which includes: Modifying the front brake lever Installing a rubber cap Removing and replacing both front and rear brake 1 i ght switches Adjusting the rear stop light switch Defect Code: 00 Flat Rate Units: Part No. 61 31 1 35 21 1 00 61 04 00 16 (1 hour, 20 459569(2ea.) 244 520 Work Package #3, which includes: Modifying the front brake lever Installing a rubber cap minutes) Removing and replacing the front brake light switch Adjusting the rear stop light switch Defect Code 00 00 61 04 00 Flat Rate Units: 13 (1 hour, 5 minutes) Part No. 61 31 1 459 569 35 21 1 244 520 Work Package #4, which includes: Modifying the front brake lever Installing a rubber cap Removing and replacing the rear brake liqht switch Adjusting the rear stop light switch ( Defect Code 00 00 61 04 00 Flat Rate Units: 11 (55 minutes) Part No. 61 31 1 459 569 35 21 1 244 520 Work Package #5, which includes: Modifying the front brake lever Defect Code: 00 00 61 04 00 Flat Rate Units: 3 (15 minutes) Work Package #6, which includes: Modifying the front brake lever Removing and replacing the front brake light switch Defect Code: 00 00 61 04 00 Fl at Rate Units: 8 ( 40 minutes) Part No.: 61 31 1 459 569 ( ( ( Additional Infonnation: Identifying Vehicles on Which Recal 1 s Have Been Perfonned: Very truly yours, S.I. 2342 – page 6 Refer to Service Information XXII/88 (2284) – Group 4 – which describes the three-part Authorization Form (SD-161). Refer to Service Infonnation XXXIV/89(2 351) – Group l – which describes marking motorcycles which have already had the reca11 performed. Brake Light Switch Recall number is: Number 7 BMWof North America, Inc. Frank Stevens Richard Dampf National Service Manager National Technical Manager FS : j e l /7 5 . 5