Honda Recalls 2024 Motorcycles Over Gear Change Arm Defect

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Honda is recalling 507 of its 2024 CB650R and CBR650R motorcycles in the United States due to a defect in the gear change arm that may prevent riders from shifting gears while riding. The recall, filed with the National Highway Traffic Safety Administration (NHTSA) under recall number 25V-107, affects motorcycles produced between June 7, 2024, and July 18, 2024. The defect arose from an improper paint application to the gear change arm, which could cause the fasteners connecting the arm to the stroke sensor assembly to loosen and potentially fall off. This issue increases the risk of a crash or injury if riders are unable to shift gears during operation.

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The defect was traced to a change in production from Japan to a supplier in Thailand, which resulted in an excessively thick paint coating on the gear change arm. This uneven surface could lead to insufficient axial force and the loosening of the nut and bolt securing the gear change arm to the stroke sensor assembly. Thai Summit Gold Press, based in Bangplee District, Thailand, is identified as the component manufacturer.

Honda began investigating the issue in July 2024 after receiving a market quality report from Europe. Following further analysis and reports of additional incidents, Honda considered the possibility that motorcycles in other regions, including the U.S., might be affected. On February 13, 2025, Honda concluded that the defect posed a safety risk and initiated the recall. There have been no reported injuries, deaths, or warranty claims related to the defect in the U.S. between January 11, 2024, and February 13, 2025.

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The remedy for the defect involves replacing the gear change arm with an improved part at authorized Honda Powersports dealers. The improved part features an additional coining process, better paint thickness control and inspection, and a revised torque procedure. Registered owners of the affected motorcycles will be contacted by mail starting April 21, 2025, and may be eligible for reimbursement if they previously paid for repairs. Dealer notifications were completed on February 14, 2025. Production corrections, including temporary measures for paint thickness control and enhanced manufacturing processes, were implemented by October 21, 2024.

Article by multiple RFHC contributors.

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