ASV levers Suzuki gsxr brake recall issues

[mushee53]

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...

[mushee53]

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...

[mushee53]

I'm not technical 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...

[mushee53]

Great

Email sent.

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

[mushee53]

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..?

[mushee53]

Great that's two

[mushee53]

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]

https://ultimatemotorcycling.com/technical-bulleti...

Just to show I'm not going mad

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

Thanks again for any feedback...

Iain

[mushee53]

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]

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]

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]

MC is Nissin..

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

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]

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

I'll update all with any info I get.

Edited by mushee53 on Saturday 20th September 14:27

[mushee53]

http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/downloa...

From Suzuki US...