Suzuki Recalls Thousands of Motorcycles Due to Headlight Noncompliance

Suzuki Motor USA, LLC is initiating a recall for 1,543 motorcycles due to a defect in the headlight assembly’s upper beam, which does not meet Federal Motor Vehicle Safety Standards (FMVSS) 108. The issue could potentially impair the vision of motorcycle operators and other drivers, thereby increasing the risk of a crash. The vehicles affected include specific models of the GSX-S1000S and DL1050.

The recall specifically impacts 23 units of the 2024 Suzuki GSX-S1000S, produced between May 15, 2023, and August 10, 2023. Additionally, 127 units of the 2020 Suzuki GSX-S1000S, manufactured from December 27, 2019, to January 18, 2020, are included. The largest portion of the recall involves 1,393 units of the 2020-2025 Suzuki DL1050, with production dates ranging from January 11, 2020, to December 13, 2024. In total, Suzuki estimates that 50% of the recalled vehicles may exhibit the defect.

The noncompliance stems from the headlamp’s upper beam exceeding the maximum allowable photometric intensity at a specific test point. According to the manufacturer’s report, this issue arose because protective tape applied to the upper beam reflector base between November 20, 2019, and January 18, 2020, to prevent wear, caused the reflector to elevate slightly. This minor elevation shifted the light distribution, resulting in an increased luminous intensity at the designated test point, which violated the standard. While no immediate warning signs are associated with this defect, the consequence of the brighter beam is a potential impairment of vision for the rider and others on the road.

The identified component, the headlamp assembly, is manufactured by Koito Manufacturing Co., Ltd., a Tier 1 supplier based in Japan. The affected part numbers for the headlamp assembly are 35100-07L0* and 35100-07L1*.

The issue was first brought to Suzuki Motor Corporation’s attention by Koito Manufacturing on July 17, 2025, after it was discovered that certain headlamps did not meet FMVSS 108 photometric requirements. Suzuki Motor Corporation subsequently conducted its own testing, which confirmed that while one test area exceeded the maximum candela limit, the overall impact on light emission was minor. Despite this, Suzuki decided to proceed with a safety recall on July 31, 2025, to address the noncompliance.

Suzuki dealers will be responsible for rectifying the issue by replacing the noncompliant headlamp assemblies with new, compliant parts. The specific method for identifying the replacement components and the timeline for implementing these corrected parts in production have not yet been determined and will be communicated in an amended report. Suzuki has also outlined a reimbursement plan for customers who may have already incurred costs to repair this condition, with details provided in a separate document.

Owners of the affected motorcycles are advised not to drive their vehicles and to park them outside, if possible, until the remedy is available. Suzuki plans to begin notifying dealers on August 22, 2025, and interim owner notifications are scheduled for August 29, 2025. Owner notification for the remedy will be on a phased recall basis. VINs of affected vehicles will be searchable starting August 11, 2025.

Article by Mel Anara, based upon information from the National Highway Traffic Safety Administration

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