Y A M A H A MOTOR C O R P O R A T I O N , U. S. A.
fi5.551 K A T C L L A A V E N U E. C Y P R E S S. C A L I F O R N I A 0 - 0 1

714/761-7.100

September 27,2006
Via Federal Express and Facsimile (7882) National Highway Traffic Safety Administration Associate Administrator for Safety Assurance 400 Seventh Street, SW Washington, DC 20590 Regarding: 2004 and 2005 Model Year Yamaha YZFRl and FZSthrough 2005 Model Year Yamaha FJRthrough 2005 Model Year Yamaha XV 1700 Throttle Position Sensor Factory Modification Campaign

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Dear Sir/Madam: The purpose of this correspondence is to provide preliminary information required by 49 CFR 573 and the National Traffic and Motor Vehicle Safety Act regarding a defect notification campaign we are initiating. We are attaching a current draft of the dealer technical bulletin and draft owners notification for informational purposes. We will send under separate cover the owners notification for Agency review/ approval prior to close of business this week. The envelope format has previously been approved by the Agency for prior campaigns. 1. Manufacturers Name: Yamaha Motor Company, Ltd. 2500 Shingai Iwata, Japan Yamaha Motor Corporation, U.S.A. 6555 Katella Avenue Cypress, California 90630 Yamaha 200412005 Model Year YZFRl & FZS600 motorcycles, 2003,2004 & 2005 Model Year FJR 1300 motorcycles, 2002,2003,2004 & 2005 Model Year XV 1700 motorcycles YZFRl is 1000cc, FZS600 is 600cc, FJR1300 is 1300cc and XV 1700 is 1700cc November 2002 - March 2005
Imported Vehicle Distributor:

Vehicles Affected:

Make: Models:
Nominal Engine Displacement: Production Period:
The campaign relates to the motorcycle's throttle position sensor (TPS). Total number of subject vehicles: Current estimate: 39,000 units. This will be updated in a supplemental report as we finalize the affected VIN range. VIlV Range: See tentative range attached in draft Technical Bulletin. Likewise this will be updated in a subsequent report as data is confirmed. The campaign involves the replacement of the throttle position sensor (TPS). Please refer to the attached draft Technical Bulletin which will be furnished to dealers upon completion describing the situation which is the subject of the campaign. On September 22,2006, Yamaha Motor Corporation, U.S.A. was informed by the manufacturer, Yamaha Motor Company, Ltd., that such a situation exists. This was determined pursuant to a quality control review, testing, collaborating with NHTSA on PE06020 and a review of models that use a substantially similarly part design. We anticipate commencing dealerlowner notification shortly after the owner's notification letter is approved by NHTSA, the affected VIN range is ascertained and the Technical Bulletin revised. We anticipate sending the Agency the owner's notification letter for reviewlapproval by 9-29-06. Assuming the Agency can approve the letter within 5 days of receipt (perhaps 10-6-06) we will have the letter and Technical Bulletin printed. Normal turn-around time is 3 working days for such printing. Hence the materials will be ready for mailing approximately 10- 11-06. Final copies of these notification documents will be forwarded to the Agency as soon as possible.
In the event we can answer any questions or provide supplemental information, please do not hesitate to contact the undersigned. My direct telephone number is 714-761-7709. The fax number is 7 14-76 1-7836. My email is russjuraayamaha-motor.com or contact Brad Franklin at 7 14-761-7842 (telephone), 7 14-229-7944 (Fax), brad-franklin@yamaha-motor.com (email). Sincerely,
Russell D. ~ u r a ~ Senior Vice President and General Counsel RDJIdlb Enclosures: CC: Technical Bulletin Owners Notification By Fed Ex and Facsimile Defects & Recall Information Analysis Division Mr. Jon White Mrs. Pat Wallace Mrs. Kelly Schuler (FAX: 202-366-0699) Mr. Robert Young (via email)

1 MOTORCYCLE

I XX/XX/O6

I M2006-XXXR

02006YAMAHA MOTOR CORPORATION, USA
XV1700PC, and 2003-2005 FJRl300lA

FACTORY MODIFICATION CAMPAIGN - Unstable Engine Idling
Yamaha Motor Corporation, U.S.A. has determined that a defect which relates to motor vehicle safety exists in all 2004 and certain 2005 YZF-RI motorcycles, in all 2004 and certain 2005 FZS6OO motorcycles, in all 2002 through 2004 and certain 2005 XVI 700PC 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 intermittently unstable idle when the engine is at idling speed when the motorcycle is stopped or during lowspeed 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 an accident with injury or death.

PRIMARY TPS

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 authorized Yamaha dealer for the modification.
IMPORTANT: Some YFZ-RI and FZ6 motorcycles were modified according to Technical Bulletin M2006-011 reimbursed with a SOTS-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 xx/xx/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.

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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 i s a violation of Yamaha policy for your dealership t o deliver any affected motorcycles to customers until the procedures i n this bulletin are performed. When the modification on each motorcycle is performed, follow the Warranty lnformation section of this bulletin 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).

D A E ACTION SUMMARY ELR

Unsold Units: Sold Units:
Exchange the TPS during predelivery set-up on all affected units if not previously done according to Technical Bulletin M2006-011. Replace the TPS on all units in the affected range, whether or not unstable idle has been experienced. 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 xx/xx/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). Yes, order one TPS per unit.

Parts Required:

Warranty: Factory Modification Campaign. See the Warranty lnformation section of this bulletin. This modification applies to all affected units not previously modified regardless of ownership or warranty status.

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AFFECTED RANGE
All RN13E-0007911-0012965 RN13Y-0001423-0003392 All RJ08E-0002249-0004781 RJ08Y-0000303-0000770' Road Star Warrior 2002 XV1700PCPlPCPC All 2003 XV1700PCRlPCRC All 2004 XV1700PCSlPCSC All VP14E-0010009-XV1700PCT XV1700PCTC All FJR 1300lA 2003 FJR1300RlRC F~lR1300S/SC/AS/ASC 2004 FJR1300T 2005 FJR 1300TC FJRl300AT FJRI300ATC All All RP07E-0002237-0003981 RP07Y-0000400-0000661 RP09E-0000873-0002293 RP09Y-0000181-0000510
YZF-RYZF-RlSISC 2005 YZF-RlT YZF-RlTC FZFZS6OOSlSC 2005 FZS6OOT FZS6OOTC
'NOTE: This affected range is different from that provided in M2006-011.

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SERVICE PROCEDURES To replace the TPS, follow the applicable Service Manual: YZF-Rl FZ6 XV1700PC LIT-11616-1 7-55 LIT-11616-1 7-50 LIT-11616-RS-WO
B e sure t o remove the o l d TPS seal from the throttle body if i t d i d not come off with the TPS. Otherwise, the leftover seal may cause the new TPS t o exhibit a n unstable idle.
When the modification is complete, put a punch mark above the VIN (frame number) as shown.
Before modifying a unit, check for this 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 Bulletin M2006-011 (2004 YZF-R1 models would have two punch marks). If you have any question about whether or not a unit is modified, check YDS or contact your Regional Technical Advisor.

PARTS INFORMATION Description TPS (includes new seal) TPS (includes new seal) TPS (includes new seal) Application YZF-R1 FZSGOO XVl700PC FRl300lA Qty. 1 Dealer Cost $70.99 $70.99 $66.71
Part Number 5FL-85885-02-00 5PX-85885-01-00 5PS-85885-01-00

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WARRANTY INFORMATION
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, regardless 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 motorcycles if the TPS was alrea.dy completed and claimed using Problem Code 90TS per the previous M2006-011 bulletin. However, effective xx/xx/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 9900xx. 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. Y DS: When signed on to YDS, click on the Service Tab, and then "Recall Request-Add." This function 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 submission 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:
Dealer Number Dealer Name

Status

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).

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6555 Katella Avenue, Cypress, California 90630-5101 (714) 761-7300

SAFETY RECALL NOTICE

XX, X X , 2006
Dear Yamaha Owner: Thts notice
sent to you In accordance wlth the requirements of the National Traffic and Motor Vehicle Safety Act. Yamaha Motor Corporation,
U.S.A. has determined that a defect which relates to motor vehicle safety exists in all 2004 and certain 2005YZF-RI motorcycles, in all 2004 and certain 2005 FZS6OO motorcycles, in all 2002 through 2004 and certain 2005 XVI700PC 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 this call: In affected motorcycles, an improperly designed Throttle Position Sensor (TPS) could cause an intermittently 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 an accident with injury or death.

A special note toYZF-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. Whatyamaha and your dealer will do: To correct this defect, your authorized Yamaha dealer will replace the Throttle Position Sensor. There will be n o charge t o 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 d o now: Please call your Yamaha dealer to make a service appointment to have this procedure performed. At that same time, you can flnd 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 authorizedyamaha 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. 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, National Hlghway Traff~cSafety Administration, 400 Seventh St. SW, Washington, DC 20590 or call the Auto Safety Hotline at 1-888-327-4236. If you n o longer own this Yamaha: If you have sold your motorcycle to another party, pkase Call us toll-free at 1-800-227-5963 with the name and 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

2004~2005 YZF-R1, 2004~2005 FZS600, 2002~2005 XV1700PC, and 2003~2005 FJR1300/A FACTORY MODIFICATION CAMPAIGN Unstable Engine Idling Yamaha Technical Bulletin M2006-016R
Yamaha Motor Corporation, U.S.A. posts this notice as a service to Yamaha customers and potential Yamaha customers. Yamaha Motor Corporation, U.S.A. has decided a defect relating to motor vehicle safety exists in all 2004 and certain 2005 YZF-R1 R1 motorcycles, in all 2004 and certain 2005 FZS600 FZ6 motorcycles, in all 2002 through 2004 and certain 2005 XV1700PC Road Star Warrior motorcycles, and in all 2003, 2004 and certain 2005 FJR1300 and FJR1300A motorcycles. Affected Models
YZF-RYZF-R1S/SC All 2005 YZF-R1T RN13E-0007911~0012965 YZF-R1TC RN13Y-0001423~0003392 FZFZS600S/SC All 2005 FZS600T RJ08E-0002249~0004781 FZS600TC RJ08Y-0000303~0000770* Road Star Warrior 2002 XV1700PCP/PCPC All 2003 XV1700PCR/PCRC All 2004 XV1700PCS/PCSC All 2005 XV1700PCT VP14E-0010009~0012298 XV1700PCTC All FJR1300/A 2003 FJR1300R/RC All 2004 FJR1300S/SC/AS/ASC All 2005 FJR1300T RP07E-0002237~0003981 FJR1300TC RP07Y-0000400~0000661 FJR1300AT RP09E-0000873~0002293 FJR1300ATC RP09Y-0000181~0000510
The reason for this recall: In affected motorcycles, an improperly designed Throttle Position Sensor (TPS) could cause an intermittently 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. What Yamaha and your dealer will do: To correct this defect, Yamaha initiated a Factory Modification Campaign. Unmodified affected motorcycles must have the TPS replaced with a new one. What you should do now: Do not operate affected motorcycles until they are modified. If you are not the first owner of the motorcycle, and are unsure if this important modification has been done, contact any authorized Yamaha Motorcycle Dealer to check. Any authorized Yamaha Motorcycle Dealer can perform this service. For the name and location of a dealer near you, call 1-800-88-YAMAHA or visit the Dealer Locator section of this website.