MOTORCYCLE 10/13/06 M2006-016R
©2006 YAMAHA MOTOR CORPORATION, USA
RECALL This modification has top priority. This bulletin must be
performed immediately to ensure customer safety.
NOTE: Bulletins that announce a recall will have an “R” at the end of the bulletin number from now on.
2004~2005 YZF-R1, 2004~2005 FZ6, 2002~2005
XV1700PC, and 2003~2005 FJR1300/A
FACTORY MODIFICATION CAMPAIGN – Unstable Engine Idling
Yamaha Motor Corporation, U.S.A. has decided that
PRIMARY TPS
a defect which relates to motor vehicle safety exists
in all 2004 and certain 2005 YZF-R1 motorcycles, in
all 2004 and certain 2005 FZS600 motorcycles, in
all 2002 through 2004 and certain 2005 XV1700PC
motorcycles, and also in all 2003 through 2004 and
certain 2005 FJR1300 and FJR1300A motorcycles.
In affected motorcycles, an improperly designed
Throttle Position Sensor (TPS) could cause an inter-
mittently unstable idle when the engine is at idling
speed when the motorcycle is stopped or during low-
speed operation. The engine could stall as a result.
If the engine stalls after the operator disengages the
clutch in a low gear while riding, the rear tire might
slip momentarily if the operator abruptly re-engages
the clutch. This could result in a vehicle crash with
injury or death.
To correct this defect, Yamaha is initiating a Factory Modification Campaign. Unmodified affected motorcycles
must have TPS replaced with a new one.
Yamaha is notifying all registered owners of unmodified affected motorcycles by mail. A copy of this letter is
included in this bulletin. The customer should take the letter along with the affected motorcycle to an autho-
rized Yamaha dealer for the modification.
IMPORTANT: Some YFZ-R1 and FZ6 motorcycles were modified according to Technical Bulletin M2006-011
reimbursed with a 90TS-code claim. The procedure and new parts used are the same as those in this recall.
Units modified with a new TPS before this recall was announced do not require any additional action now.
Effective 10/16/2006, the previous Technical Bulletin M2006-011 is no longer valid and the 90TS code can no
longer be claimed. Make a note on your copy of M2006-011 to refer to this bulletin instead.
PAGE 1 of 5
A computer report listing all affected motorcycles invoiced to your dealership is included with this bulletin.
Use the list to help ensure all motorcycles are modified. All sold motorcycles that have been registered with
Yamaha will show the customer’s name and address. Your dealership must notify the owner of any affected
motorcycle that was actually sold but is listed as “unsold” in the report.
You must modify all affected motorcycles in your inventory as well as all customer-owned motorcycles brought
to you for this service. Any affected motorcycle that you purchase from Yamaha in the future will also require
modification. If you purchase a motorcycle from another dealer, check to see if the procedures in this bulletin
have already been performed before you sell the motorcycle.
Motorcycles that are affected should not be operated until they are modified. It is a violation of Yamaha
policy for your dealership to deliver any affected motorcycles to customers until the procedures in
this bulletin are performed.
When the modification on each motorcycle is performed, follow the Warranty Information section of this bul-
letin to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in Chapter 8 of
the Warranty and Y.E.S. Handbook (LIT-11760-00-04).
Unsold
Units: Exchange the TPS during predelivery set-up on all affected units if not previously done according
to Technical Bulletin M2006-011.
Sold
Units: Replace the TPS on all units in the affected range, whether or not unstable idle has been experi-
enced. A letter is being mailed to all registered customers. A copy of the letter is included in this
bulletin. Please contact any customers whose units were registered for warranty after 10/12/06.
Before beginning the modification, verify that the modification has not been performed already
by checking YDS and the motorcycle (refer to Identification Procedure section, page 3).
Parts
Required: Yes, order one TPS per unit.
Warranty: Factory Modification Campaign. See the Warranty Information section of this bulletin. This modi-
fication applies to all affected units not previously modified regardless of ownership or warranty
status.
YZF-R1 Road Star Warrior
2004 YZF-R1S/SC All 2002 XV1700PCP/PCPC All
2005 YZF-R1T RN13E-0007911~0012965 2003 XV1700PCR/PCRC All
YZF-R1TC RN13Y-0001423~0003392 2004 XV1700PCS/PCSC All
FZ6 2005 XV1700PCT VP14E-0010009~0012298
2004 FZS600S/SC All XV1700PCTC All
2005 FZS600T RJ08E-0002249~0004781
FZS600TC RJ08Y-0000303~0000770* FJR1300/A
2003 FJR1300R/RC All
2004 FJR1300S/SC/AS/ASC All
2005 FJR1300T RP07E-0002237~0003981
FJR1300TC RP07Y-0000400~0000661
*NOTE: This affected range is different from that provided FJR1300AT RP09E-0000873~0002293
in M2006-011. FJR1300ATC RP09Y-0000181~0000510
PAGE 2 of 5
To replace the TPS, follow the applicable Service WARNING
Manual:
Be sure to remove the old TPS seal from the
YZF-R1 LIT-11616-17-55 throttle body if it did not come off with the TPS.
FZ6 LIT-11616-17-50 Otherwise, the leftover seal may cause the new
XV1700PC LIT-11616-RS-W0 TPS to exhibit an unstable idle.
FJR1300/A LIT-11616-FJ-02
RUBBER SEAL
When the modification is complete, put a
punch mark above the VIN (frame number) 1
as shown.
Before modifying a unit, check for this punch
mark. 1
PUNCH MARK
NOTE: On YZF-R1 and FZ6 motorcycles, also
check for a punch mark at the beginning of the
VIN which would indicate that the procedure
was done under the original Technical Bulle-
JYAVP02E000012XXX
tin M2006-011 (2004 YZF-R1 models would
have two punch marks). If you have any ques-
tion about whether or not a unit is modified,
check YDS or contact your Regional Techni-
cal Advisor.
Part Number Description Application Qty. Dealer Cost
5FL-85885-02-00 TPS (includes new seal) YZF-R1 1 $70.99
FZS600
5PX-85885-01-00 TPS (includes new seal) XV1700PC 1 $70.99
5PS-85885-01-00 TPS (includes new seal) FR1300/A 1 $66.71
PAGE 3 of 5
The owner of each warranty-registered unit shown as not modified in our records will receive a
letter announcing this campaign. The letter has a label that includes the Primary ID and Recall
Number. Use this information when submitting for reimbursement as described below.
The modification is authorized for all unmodified affected vehicles, both sold and unsold, re-
gardless of ownership or warranty status. You do not need the customer’s letter to perform the
modification or to file for reimbursement.
NOTE: Completing this recall modification is not necessary on affected YZF-R1 or FZ6 motorcy-
cles if the TPS was already completed and claimed using Problem Code 90TS per the previous
M2006-011 bulletin. However, effective 10/16/2006, Technical Bulletin M2006-011 and Problem
Code 90TS are no longer valid.
Submit a Recall Request for the TPS replacement as described below using Recall Number
990034. Choose the status “M.” You will be reimbursed for 1.2 hours of labor, plus the cost of the
TPS kit and your handling fee.
YDS:
When signed on to YDS, click on the Service Tab, and then “Recall Request-Add.” This func-
tion will allow you to enter multiple Primary IDs for the same recall. Remember that YDS now
requires a 7-digit serial number, so use a “0” as the first digit. The system will check your submis-
sion instantly to make sure the Primary ID numbers you’ve entered are valid for the recall. You
can check back the next day for your claim numbers to track your credit.
MAIL:
Complete a recall Reimbursement Request (LIT-11790-00-03) as shown below:
9 9 0 0 3 4 RN 1 3E 0 0 0 7 X X X 1 0 1 7 2 0 0 6
If you have any questions about proper procedures for Factory Modification Campaigns, see
Chapter 8 in your Warranty and Y.E.S. Handbook (LIT-11760-00-04).
PAGE 4 of 5
6555 Katella Avenue, Cypress, California 90630-5101 (714) 761-7300
SAFETY
SAFETY RECALL
RECALL NOTICE NOTICE
October 13, 2006
April 16, 2004
Dear Yamaha Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Yamaha Motor Corporation,
U.S.A. has decided that a defect which relates to motor vehicle safety exists in all 2004 and certain 2005 YZF-R1 motorcycles, in all 2004 and
certain 2005 FZS600 motorcycles, in all 2002 through 2004 and certain 2005 XV1700PC motorcycles, and also in all 2003 through 2004 and
certain 2005 FJR1300 and FJR1300A motorcycles. Our records show that you own one of these motorcycles.
The reason for In affected motorcycles, an improperly designed Throttle Position Sensor (TPS) could cause an intermittently unstable
this call: idle when the engine is at idling speed when the motorcycle is stopped or during low-speed operation. The engine
could stall as a result. If the engine stalls after the operator disengages the clutch in a low gear while riding, the rear
tire might slip momentarily if the operator abruptly re-engages the clutch. This could result in a vehicle crash with
injury or death.
A special note to YZF-R1 and FZ6 owners: If you responded to a previous letter from Yamaha dated July 26, 2006,
regarding the TPS, and your dealer has already replaced the TPS assembly on your motorcycle, you do not need to
respond to this letter because it involves the same modification.
What Yamaha and To correct this defect, your authorized Yamaha dealer will replace the Throttle Position Sensor. There will be no
your dealer will do: charge to you for this procedure. The procedure takes approximately 1 hour and 45 minutes to perform, depending
upon the model, but your dealer may need to keep your motorcycle longer depending upon his schedule.
What you should do Please call your Yamaha dealer to make a service appointment to have this procedure performed. At that same time,
now: you can find out how long he expects he will need to keep your motorcycle for this service. Remember to take this
letter with you when you take in your motorcycle.
You should not ride your motorcycle until this modification is performed.
If you are unable to return to the Yamaha dealer who sold you the motorcycle, this service will be performed by any
authorized Yamaha Motorcycle dealer. For the name of a dealer near you, call 1-800-88-YAMAHA or visit the Yamaha
web site at: www.yamaha-motor.com.
Federal regualtions require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the
lessee within 10 days.
If you need help: If, after contacting your dealership, you have questions or concerns which the dealership is unable to answer, please
write to:
Yamaha Motor Corporation, U.S.A.
Customer Relations Department
P.O. Box 6555
Cypress CA 90630
If, after contacting Yamaha Customer Relations, you are still not satisfied that we have done our best to remedy the
situation without charge and within a reasonable time, you may submit a written complaint to the Administrator, Na-
tional Highway Traffic Safety Administration, 400 Seventh Street, SW., Washington, DC 20590; or call the Auto Safety
Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.
If you no longer If you have sold your motorcycle to another party, please call us toll-free at 1-800-227-5963 with the name and
own this Yamaha: address of the new owner, along with the serial number shown above your name on the address label above.
We’re sorry to cause you any inconvenience, but we are sincerely concerned about your safety and continued satisfaction with our products.
Thank you for giving your attention to this important matter.
Sincerely,
Customer Support Group
Yamaha Motor Corporation, U.S.A.
PAGE 5 of 5
