Honda Recalls Thousands of Motorcycles Due to Potential Loss of Critical Functions

American Honda Motor Co. is initiating a safety recall for over 7,000 of its CRF1100 model motorcycles due to a defect that could lead to the loss of horn function and the inability to switch between low and high beams on the headlight. This recall, identified by NHTSA Recall Number 25V583 and manufacturer recall number KS8, encompasses specific model years and impacts a significant number of vehicles.

The issue stems from the left handlebar switch harness, which, under normal use, can develop oxide due to repeated bending at terminal joint locations. This process, known as fretting corrosion, can disrupt electrical connections, leading to the malfunction of essential controls. The safety risk associated with this defect is considerable; a non-functional horn prevents riders from warning other vehicles of potential hazards, thereby increasing the likelihood of a crash. Similarly, a compromised headlight function that prevents switching between beams can reduce a rider’s visibility, also raising the risk of an accident. Honda notes that intermittent loss of horn and headlight function may serve as a warning sign of this issue.

The vehicles affected by this recall include the 2020-2022 Honda CRF1100 and the 2024-2025 Honda CRF1100. A total of 4,337 units of the earlier model range and 3,155 units of the later model range are potentially involved, bringing the total number of potentially affected motorcycles to 7,492. The production dates for the affected 2020-2022 models range from August 28, 2019, to July 21, 2022, while the 2024-2025 models were produced between February 09, 2024, and February 06, 2025. The recall population was determined based on manufacturing records to ensure all possible vehicles experiencing the problem are identified.

Honda’s investigation into this issue began after reports of intermittent horn malfunctions in Europe in June 2022. While initial investigations did not reveal abnormalities, further reports in early 2023 prompted a deeper inquiry. By October 2023, abnormal resistance values were detected at the horn joint, leading Honda to investigate the handlebar switch assembly more closely. Extensive testing, including the use of strain gauges, eventually confirmed in November 2024 that relative motion at the crimp under load creates conditions for fretting wear, directly linking harness continuity failures to applied loads. On August 28, 2025, Honda officially determined that a safety defect and noncompliance with Federal Motor Vehicle Safety Standards existed, necessitating this recall. As of August 28, 2025, Honda has not received any warranty claims or reports of injuries or deaths in the U.S. related to this specific issue.

To address the defect, Honda will replace the left handlebar switch assembly with an improved part that has been redesigned to eliminate the use of joint terminals in the harness. Registered owners of all affected vehicles will be notified by mail and instructed to take their motorcycles to an authorized Honda Powersports dealer for the repair. The company began notifying dealers on or about September 2, 2025, and owner notifications are scheduled to commence around November 3, 2025, with the remedy phase expected to conclude by January 30, 2026. Information regarding specific vehicle identification numbers (VINs) will be searchable starting September 15, 2025. The fix is expected to be implemented in production starting with the 2026 CRF1100 Africa Twin motorcycles manufactured from September 17, 2025.

Article by Mel Anara, based upon information from the U.S. Department of Transportation National Highway Traffic Safety Administration.

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