ASV levers Suzuki gsxr brake recall issues

ASV levers Suzuki gsxr brake recall issues

Author
Discussion

mushee53

Original Poster:

65 posts

152 months

Friday 19th September 2014
quotequote all
Hi All,

I've got short ASV levers and had the brake recall done (front master) K4 gsxr and the dealer is struggling to get hold of a new pin to enable the use of the ASV lever again, so I've got a standard lever replacement which is naff...

They wouldn't refit the ASV, something todo with risk of failure due to the wrong size pin etc..

So my question is... dealer says ASV don't have a resolution for the issue... Dealer has other bikes waiting with a similar issue... Anyone know a fix for this..

Apparently the new pin from ASV is the same as the old pin.... i.e. Doesn't fit...

Any ideas...

10penceparalyzed

229 posts

123 months

Friday 19th September 2014
quotequote all
can't you find a engineering company near to you than can machine one to the spec required?

mushee53

Original Poster:

65 posts

152 months

Friday 19th September 2014
quotequote all
Trouble is I don't know what that spec is... Under the impression every ASV lever can't be used with the brake recall so hoping someone on here can tell me differently...

Mr OCD

6,388 posts

210 months

Friday 19th September 2014
quotequote all
Same MC? Seems odd it won't fit anymor ...

mushee53

Original Poster:

65 posts

152 months

Friday 19th September 2014
quotequote all
I'm not technical frown but the dealer said using the old pin would lead to a brake failure... Apparently agreed by Suzuki HQ

Seems odd though that this hasn't been resolved... I remember reading a blog from ASV saying they had engineered a new pin but now apparently performance parts their UK distributor doesn't have a fix...

Surely though that means any ASV lever now can't be used with a Gsxr that's had the brake recall.... Which I'm struggling to believe...

podman

8,850 posts

239 months

Friday 19th September 2014
quotequote all
In this situation, I would cut out the middleman (the dealer )and contact the manufacturers directly.

Performance parts import ASV levers according to the net, Suzuki GB are based in MK.

I would email the pair of them, together, in one email and see what they both have to say..

Sounds extreme but a few years I had a problem with a dealer and copied in BBC Watchdog, now BBC Watchdog take up very few cases but it does make the organisation involved sit up and take notice (I know, I was head of a customer complaints department in a former life)..it wouldnt be the first time Suzuki have made Watchdog over a recall anyway!

mushee53

Original Poster:

65 posts

152 months

Friday 19th September 2014
quotequote all
Great smile

Email sent.

Please anybody with any other info let me know though...

mushee53

Original Poster:

65 posts

152 months

Friday 19th September 2014
quotequote all
This is what I was hoping for... The dealer asked me "was it the original pin" (no idea what pin) from the original install but I didn't know., Steve Jordan motorcycles did the original ASV install... Hazelmere spoke to performance parts for a 'new' pin and apparently there is no 'new' updated pin so hazelmere can't refit the lever...

Can you let me know the official suzuki dealer that did yours... So I can contact them re: advice..?

StuB

6,695 posts

238 months

Friday 19th September 2014
quotequote all
My ASV lever fitted OK!

mushee53

Original Poster:

65 posts

152 months

Friday 19th September 2014
quotequote all
Great that's two smile

StuB

6,695 posts

238 months

Friday 19th September 2014
quotequote all
Just a guess you have counterfeit ASV levers?

mushee53

Original Poster:

65 posts

152 months

Friday 19th September 2014
quotequote all
I doubt Steve Jordan motorcycles would supply fake levers...quite a well known race specialist in the south... Plus the Suzuki dealership has 4 other bikes with the same issue pending...

This is my confusion... There is evidence on the web the fault exists but no clear understanding from a Suzuki dealer and the ASV importer...

As suggested I've emailed Suzuki HQ and performance parts... Will update..

Good to hear others have them fitted though... So there must be an answer/fix out there...

Bikes in storage now so pic's are an issue...

mushee53

Original Poster:

65 posts

152 months

Saturday 20th September 2014
quotequote all
https://ultimatemotorcycling.com/technical-bulleti...

Just to show I'm not going mad smile

However apparently the new pin from ASV doesn't fix the problem..

Thanks again for any feedback...

Iain

mushee53

Original Poster:

65 posts

152 months

Saturday 20th September 2014
quotequote all
Exactly my point and why I let them put a standard lever on instead of the ASV, they were quite adamant it could cause a full brake failure if they left the ASV on... So is new MC a redesign that doesn't fit the ASV lever officially ??

Don't get me wrong Hazelmere has kept me in the loop as they chase up the matter... but scares me to think others are just having the work done and are unaware the problem may exist...

I'm on here as always found pistonheads is good for real info...

Done a few more web searches tonight and there is def an issue with ASV levers and the brake recall...



Edited by mushee53 on Saturday 20th September 00:40

mushee53

Original Poster:

65 posts

152 months

Saturday 20th September 2014
quotequote all
From the link:


Recently recalled 2004 to 2009 Suzuki GSX-R600, GSX-R750 and GSX-R1000 motorcycles fitted with ASV Inventions brake levers before the recall can potentially have issues if the original ASV brake plunger rod on the recalled brake master cylinder is not reinstalled on the replacement.

Furthermore, the plunger rod on Suzuki’s recall-mandated brake master cylinder must not be used with any ASV lever.

ASV recommends that GSX-R owners with ASV brake levers re-mounted on upgraded master cylinders return to the dealer that installed them to ensure that the ASV lever’s original plunger rod was used.

Installation of ASV brake levers on the new master cylinders must be performed according to ASV’s installation instructions, which can be found at ASVinventions.com.

If the original ASV plunger rod wasn’t used and the dealer no longer has the ASV-supplied part, a replacement will be sent free of charge.

To receive this part or get more information regarding the recall exchange and installation of an ASV brake lever, please contact ASV Inventions at 714-861-1400.


So... Hazelmere say the original ASV rod is still not suitable.... But as I have no idea what these parts do etc I'm still confused...

mushee53

Original Poster:

65 posts

152 months

Saturday 20th September 2014
quotequote all
Nope, dealer fitted...just got the box's...

If that's true then just need to refit stock rod.... job done.... But nope... This isn't the case for me or the other owners waiting to have them refitted...

Confusion continues...

mushee53

Original Poster:

65 posts

152 months

Saturday 20th September 2014
quotequote all
MC is Nissin..

Just dug ASV lever out, can't post pic... frown

My barrel looks slightly oval at the mouth for the rod compared to your pic...

Weird the rod in yours is fixed if the article suggests its replaceable...

Thanks for the help though...

Hoping I get some answers from Suzuki HQ and performance parts soon....

mushee53

Original Poster:

65 posts

152 months

Saturday 20th September 2014
quotequote all
Just spoken to Steve Jordan motorcycles too as they fitted the original ASV levers.. Going to get the bike out of storage and get it to them to investigate...

Fingers crossed smile

I'll update all with any info I get.

Edited by mushee53 on Saturday 20th September 14:27

mushee53

Original Poster:

65 posts

152 months

Saturday 20th September 2014
quotequote all

Mr2Mike

20,143 posts

254 months

Saturday 20th September 2014
quotequote all
anonymous said:
[redacted]
It will be down to the length of the plunger rod. If it's too long when combined with the ASV lever, it will result in the MC piston being slightly pushed in all the time which can cover the transfer port that allows fluid back into the reservoir. As the brakes and fluid heat up, this results in the caliper pistons being forced out and the brakes will start binding, which gets the fluid hotter so they bind some more until the brakes eventually lock up the wheel. This is the same problem that quite a few of people have discovered when using badly machined Chinese levers.

You need to be absolutely sure that there is a small amount of clearance between the plunger rod and piston with the brake lever at rest. If not, then simply shortening the plunger rod would fix the problem. You could check this by taking the pads out of one caliper and seeing if you can easily push the pistons back into the caliper - if not then you can expect problems.