FJRF003.0: Ignition Failures on FJRs

[JHMZ71]

1. 2007
2. 15K

3. Failed running in traffic in Dallas on Friday evening

4. Switch Failure

5. New switch / metric tech (warranty out in Feb.)

6. 2 weeks for part

7. paid by me

8. no extra accessories

9. two keys

10. 2 weeks driving the truck with $150.00 dollars gas @ 16 mpg

Called Yamaha customer service and they say there is no record of any failures of this type on the FJR.

Just filed my complaint with the NHTSA.

 

[dcarver]

"Called Yamaha customer service and they say there is no record of any failures of this type on the FJR."

What a bunch of crap on Yamaha's part. I've spoken directly with Cypress several times. I'm a nobody, so they haven't paid attention. Still, I have faith corporate will make good; their track record is good with tickers and other issues. It just takes time. I hope mamma Yamma comes through again.

In the meantime, carry *****, tape, wire nuts and wire. (or install an ignition relay).

 

[JHMZ71]

Actually the plastic housing that holds all the wires broke. Thus, a whole new ignition switch had to be installed. Time for Yamaha to stand up to the plate. May not help me any but, may keep someone else from getting killed. Will post pictures in a dya or so.

 

[Checkswrecks]

Called Yamaha customer service and they say there is no record of any failures of this type on the FJR.Just filed my complaint with the NTSB.

PaleRider used the NTSB acronym and then caught his own mistake, because the NTSB is the wrong agency for this. They investigate accidents and do not collect this kind of data. He rightly cited NHTSA in a subsequent post. John T deserves a lot of credit for actually pursuing NHTSA on the issue, so they can log these failures, even if we may argue about the groupings.

Never having had a switch failure (to the sound of knocking on wood), I'd not been following these threads till a couple of days ago when thinking about my new '07. To prevent double-posting, the following is clipped from what I wrote in another thread:

[SIZE=10pt]The only way to get action on this one is for lots of people to log their actual problems with NHTSA on the www.safercar.gov [/SIZE]site! We've got 11 pages of people logging these problems on this forum, but unfortunately the reports die there. To get something to happen, each of you need to log your occurence with NHTSA. It has to be each of you as individuals, because you need to have your model info and VIN #. These reports are also collected by each of the manufacturers, which means that Yamaha will pay attention.

Bob

 

[ponyfool]

1. 2006
2. Roughy 12,500
3. Failed after getting gas (in the middle of no where) 1800 miles from home!
4. Appears solder connection failed (hasn't been verified yet)
5. Did roadside repair myself (hot wired it) Yamaha has not been notified at this point
6. Not yet at the dealer
7. They WILL pay for a new, re-keyed ignition!
8. Not much, a Starcom and Zumo
9. Hasn't been addressed yet
10. Without this forum, I would probably still be stranded in SE Colorado walking in circles babbling. Because of this forum, I was able to identify which wires to cut and hot wire. I'm still on my 5000 mile trip and haven't returned home yet, but I'm very worried about someone simply walking up and stealing the bike with the ignition bypassed.

 

[ponyfool]

NOTE: I just did a search of complaints on the NHTSA website, and using their searchable complaint database, the ONLY Yamaha they have a registered complaint on is a YP400. WTF?

 

[dcarver]

NOTE: I just did a search of complaints on the NHTSA website, and using their searchable complaint database, the ONLY Yamaha they have a registered complaint on is a YP400. WTF?

Curious. I know I've filed my complaint. :angry:

 

[SockMonkey]

NOTE: I just did a search of complaints on the NHTSA website, and using their searchable complaint database, the ONLY Yamaha they have a registered complaint on is a YP400. WTF?

NOTE: I just did a search of complaints on the NHTSA website, and using their searchable complaint database, the ONLY Yamaha they have a registered complaint on is a YP400. WTF?

Curious. I know I've filed my complaint. :angry:

Apparently, there have been several recall campaigns attributed to Yamaha over the last few years according to the NHTSA database. None of them however relates to failed ignition switch assemblies (though I was surprised to learn of the '06 recall of '03 - '05 FJRs for throttle position sensor. I probably read about it here somewhere just really never paid much attention since I own an '07...).

Apart from Yamaha, the NHTSA is one of the very few organizations that knows exactly how many FJRs of each model year have been sold in the US. That's part of its job. Thus when viewed as a percentage of the number of bikes sold, a complaint or 2 may not get much attention and may not even get a public file opened in the near term. A dozen or more complaints however - particularly when filed within the span of only a few months, will get their attention much more rapidly. That's why it's so important that a complaint be filed as soon as possible by every owner that has experienced a legitimate ignition failure, or has experienced a problem with their FJR that can be positively identified as stemming from a malfunctioning ignition switch assembly. From prior experience, it can take the NHTSA anywhere from a couple of weeks to several months to open a public file and collate the complaints depending on complaint volume and severity of the issue.

I would like to stress that FJR owners should not file a complaint unless they have actually experienced an ignition failure, or have experienced a problem with their FJR that has been positively identified as stemming from a malfunctioning ignition switch assembly. Filing a complaint out of concern an ignition switch failure might occur, or filing a complaint because an entirely unrelated problem is being attributed to an ignition switch malfunction will only result in the NHTSA taking more time to sort through filed complaints, and give Yamaha wiggle room when being pressured by the NHTSA to fix the problem. Please don't dilute an honest attempt at forcing a recall campaign with "concerned owner" complaint filings, or complaint filings made because of misdiagnosed problems.

 

[ShinyPartsUp]

NOTE: I just did a search of complaints on the NHTSA website, and using their searchable complaint database, the ONLY Yamaha they have a registered complaint on is a YP400. WTF?

Repeat of my August 1 post:

"I submitted an online complaint for my 2006 this week. It allowed me to put the year in and then a blank space took my FJR1300A as the model.

EDIT: I checked the NHTSA site and 15 complaints on the 2006 model FJR are listed. Eleven refer to the ignition switch problem. 39 reports for 2007 "FJR13" models, and three are regarding ignition switch failures. 2008 model FJR not listed. I did not check GEN I model years. I would assume there would be more 2006 failure reports than 2007 because of mileage/use, but I hope all are filing the relatively simple online complaint to NHTSA. All you need from the bike is your VIN and the mileage. "

I found the complaints. Mine was there from last week. And it was NHTSA site.

 

[1911]

Ignition switch just failed on my 2007 FJR. 15000 miles, in service since Oct 2007. Pulling away from light in heavy traffic and every thing shut off. Three things I'm thankful for: 1- I didn'nt get rear ended. Considering the sudden and severe deceleration caused by engine braking and lack of tail/brake lights, this could have easily happened. 2-I wasn't in a turn. 3-This didn't happen during the bikes previous outing. Failure occured the first time the bike left the garage after returning from a 1200 mile trip.

Part on order and appointmet scheduled. Will update after repairs complete. Complaint filed with NHTSA.

Two questions: 1-How did those who ended up with just 1 key after switch replacement do it, locksmith? 2-Phone number for Cypress?

 

[kulwen]

How did those who ended up with just 1 key after switch replacement do it, locksmith?

My dealer took my key and the new switch to a locksmith. The locksmith drilled the the bolts holding the switch togetther and re-keyed the ignition.

 

[Rls]

Regarding the NHTSA recall attempt. The September 08 issue of cycle world shows that the 08 Hayabusa has been recalled for "improper routing of the ignition-switch wiring harmess. Repeated side to side movement can casue the ignition switch lead to become cut or broken. Causing a intermittent or complete loss of power--sound familiar? It would seem that we are not alone on this. I would suggest that if you have had one fail to to go to the NHTSA website and record it,.

 

[mr.paul]

As far as the rekeying goes, try and get your dealer to foot the bill or have Yamaha do it. My service guy felt he ran into a roadblock with Yamaha, so he did something different. He cut the old key profile on one side of a keyblank and the new ignition switch profile on the other edge. Because the locks only use one side of the key, I have "one" key that fits all of my locks. I just have to flip the key into the right orientation. This has actually been quite easy. I ran a red Sharpie in the groove on one side of the key so that I can see which end is "up". As it happens, the ignition and the gas cap are opposite in orientation, so when I pull the key out of the ignition at a fuel stop, I can just put it directly in the cap and open it. If you didn't already know they were different, you probably wouldn't even notice.

For those that have been handed two keys, I would highly recommend having new keys made in the same "dual" fashion.

paul from Minnesota

 

[Nick06FJR]

1) What year FJR?; 2006

2) How many miles?; 19,500

3) Failed while running? Or while turning ignition? Or whatever?; Parked overnight in my garage (lucky I guess)

4) Type of failure: Wires pulled out? Switch failure? Unknown? (pictures are useful); Switch failure. Completely dead.

5) Actual repair performed and by what dealer; Dealer replaced switch; Pete's Cycle, Bel Air, MD

6) How many days was the bike at the dealer for service?; 2 weeks

7) Paid for by Yamaha or not? No, I paid $400, 1 hour diagnosis, 2 hours replacement plus part and shop fees.

8) Non-OEM accessories added that contribute to electrical draw; No

9) What did you do about the other locks (gas, side bags, seat and top case) on the bike (do you have two keys or one)? 2 keys now

10) Briefly, how badly were you inconvenienced by this ignition failure. When you use the bike for daily commuting, it was definantly an inconvenience.

 

[wambow]

Year-2006

Miles-15,891

Ignition switch failed after fueling bike.

Type of falure: Unknown haven't went into switch.

Repair- Rocky Mountain Yamaha in Pueblo,Co by passed switch with toggle switches.

How many days-2 days

Paid for by Me.

Switch on order will probably have two keys.

Inconvenienced: While on my trip back from NAFO I was heading to San Isabel, Co to vist relatives. I pulled into a convenience store late in the evening in Colorado City,Co to fuel up.(July 31 Thur) When I turned on the key after fueling nothing. Rancher and his friend at the store was very helpful. I explained my problem to them. They helped me push my bike to the rancher's friend's house about a half a block away, where I left it for the night. The rancher also gave me a ride to the local motel for the night. I was able to get in touch with relatives the next day, called towing service and had bike trailered 50 miles to dealer in Pueblo,Co. I was fortunate to only be about 10 miles from relatives when switch failed. Could have been alot worse. Could have failed in the middle of Utah desert a couple days before.

Picked up bike on Tuesday morning. Left Pueblo,Co heading home to Mississippi. Last day on road and about 10 miles from crossing Ms River at Vicksburg, running 75 mph in left lane of I20; bike shuts down. Lucky; no cars are trucks around. Go over to right shoulder and coast to an exit. One of the toggle switches has shorted out. Removed switch, twist wires together and tape. Came on to the house.

 

[wambow]

Reported problem to NHTSA.

 

[dcarver]

Year-2006
Miles-15,891

Ignition switch failed after fueling bike.

Type of falure: Unknown haven't went into switch.

Repair- Rocky Mountain Yamaha in Pueblo,Co by passed switch with toggle switches.

How many days-2 days

Paid for by Me.

Switch on order will probably have two keys.

Inconvenienced: While on my trip back from NAFO I was heading to San Isabel, Co to vist relatives. I pulled into a convenience store late in the evening in Colorado City,Co to fuel up.(July 31 Thur) When I turned on the key after fueling nothing. Rancher and his friend at the store was very helpful. I explained my problem to them. They helped me push my bike to the rancher's friend's house about a half a block away, where I left it for the night. The rancher also gave me a ride to the local motel for the night. I was able to get in touch with relatives the next day, called towing service and had bike trailered 50 miles to dealer in Pueblo,Co. I was fortunate to only be about 10 miles from relatives when switch failed. Could have been alot worse. Could have failed in the middle of Utah desert a couple days before.

Picked up bike on Tuesday morning. Left Pueblo,Co heading home to Mississippi. Last day on road and about 10 miles from crossing Ms River at Vicksburg, running 75 mph in left lane of I20; bike shuts down. Lucky; no cars are trucks around. Go over to right shoulder and coast to an exit. One of the toggle switches has shorted out. Removed switch, twist wires together and tape. Came on to the house.

Hey Wambow, sorry to hear you joined the failed ignition switch club. This must have happened after we met in CO? Very nice to meet and ride with you, good to hear you made it back home.

 

[FoolJustRide]

My ignition switch started to fail about 4 weeks ago after the bike sat outside overnight (covered) went to start the bike turned the key nothing. After messing with it for about five minutes everything lit up. Sprayed some WD40 in the switch when I got home from work as I had ridden recently in the rain. That worked up until this weekend it started acting up when I was on a trip 300 miles from home. did the WD40 thing again as we got caught in a torrential downpour the day before. Worked fine until I stopped for about an hour on Saturday and would not work at all. I ended up cutting the wire ties that hold the wiring harness leading into the switch and borrowing a wire tie from a guy on a "Harley" to pull the wire to the right side of the switch so the would make contact. The switch will not make contact when the bike is cold but works without failure when the bike is warm. Made it home today with no problems on the road just had to wiggle the wires in the morning to start the bike.

Also with the key in the ignition when to display is on if you wiggle the key the display goes off and on so I think it is in the switch.

Year: 2007

Miles: 12000

I am going to call the dealership tomorrow and see what happens. Hopefully Yamaha and the dealership will stand behind thier product.

I will let you know how it goes.

 

[tripntx]

Year 2006 AE model

10,872 miles

No power after stopping on side of road to get a drink of water

Unknown how switch actually failed. Edited 30Aug08 Dealer didn't open the switch up.

Edited 12Aug08, using Texas Yamaha South on FM528 (Nasa Rd 1).

Edited 12Aug08, dealer stated they would want it 1 day. Edited 30Aug08, dealer kept the bike for 24 hrs.

YES will have to pay. Edited 30Aug08, YES paid.

Edited 12Aug08, dealer took spare key, stated he would have ignition switch rekeyed before having me bring bike in for repair. EDITED 30Aug08, dealer had ignition rekeyed before scheduled in for repair.

Riding with 3 Goldwings, 1 M109, and 1 Verseys, my FJR was the only bike to break down. Caught some grief from all of them.

Complaint failed on Safecar.gov, complaint number 10237615

Here's what I filed with them:

Ignition Switch failed, which stranded my wife and I 20 miles north of Leakey Texas on RD 336, which is an open cattle range area where cell phone's don't have coverage, in the middle of a 100 degree day on 9 August 2008. Had stopped on the side of the road to get a bottle of water out of the saddle bag, when ignition switch turned back to "on" position, nothing happened. Had already learned from this site that Yamaha FJR's have a known problem with ignition switch failures. Cut into the wire harness coming from the ignition switch, cut the brown and red wires, and spliced in a 30 amp toggle switch, which bypassed my ignition switch and restored power. Learned about the need to carry parts to bypass the switch due to all the ignition switch failures reported on this site.

Edited 11Aug08 to add:

Called Yamaha Customer Relations at 800-962-7926, gave them the info, person I spoke to placed me on hold while he consulted a RTA, he then told me switch would be covered under YES warranty and said to have my dealer work with their assigned RTA to have my switch re-keyed through a quality locksmith to have one key for all locks. He then said RTA stated "all the ignition switch failures he had seen where from lack of lubrication, that the ignition switchs needed to have an occassional lube with WD40 or a light oil". I about came unwound. Had him retalk with RTA, and ask RTA how lubing upper mechanical portion of ignition would prevent electrical contacts &/or solder points to fail in lower half. On hold again while they talked, then was told that RTA hadn't seen the type of failure I was speaking about, which is a very rare failure as he put it. He then told me Yamaha was always seeking ways to improve their product and that they would have a solution to this problem in the future, but would not elaborate. I then asked him what to do when it went out again after my YES expired, he said to call back to customer relations and it could be worked (very important to those who haven't purchased YES warranties". Finally, I asked him what would happen if an ignition switch went out while under power on a busy road, in a turn, or crossing an intersection, and he said he didn't want to think about the outcome.

Edited 12Aug08 to add:

Using Texas Yamaha South on FM528 (NASA RD 1), they ordered ignition switch, took my spare key, said they would have ignition rekeyed before having me bring my bike in for repair, stated they would need it for 1 day. They were concerned about the fact I had cut into the wire harness, but I let them know that YES was aware of it.

Edited 30Aug08 to add:

Dealer kept my bike 24 hrs, YES paid, was switch was rekeyed prior to my bringing bike in.

 

[Zorlac]

My 2005 has 31K on it and has cranked without starting a few times over the past year.

Yesterday it threw a code 19 (sidestand switch), well the sidestand switch is OK, but the safety interlocks for clutch, neutral, and sidestand are routed through the other set of contacts on the ignition switch to the ECU.

I pulled the small wire pair connector from the ignition switch and when I ohmed out the switch, it was intermittent.

I filed a NHTSA complaint (ODI Number) is: 10237610.