Recall 16V878 affects 8,613 2012-2016 Suzuki DL650 motorcycles for alternator stator wiring that can short. Repair is free at any franchised Suzuki dealer.
Suzuki is recalling 8,613 2012-2016 DL650 motorcycles because the alternator stator has insufficient heat resistance, which can short circuit the stator wires. If the battery stops charging, the engine can stall and raise crash risk; Suzuki dealers will replace the stator free of charge.
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What's wrong?
The alternator stator on 2012-2016 Suzuki DL650 motorcycles is the stationary coil inside the charging system. As the engine turns the alternator, the stator helps generate electrical power for the motorcycle and keeps the battery charged while you ride. Its wiring has to handle heat from the engine and electrical load without breaking down.
On affected DL650 motorcycles, the stator wiring did not have enough heat resistance. Suzuki traced the issue to glue applied outside the stator wiring before impregnating resin was added; that process let resin collect inside the glue instead of protecting the wiring as intended. With heat and use, the stator wires can short circuit, meaning electrical current takes the wrong path through damaged insulation.
There is no warning sign before failure. The first sign for an owner is the charging system no longer working as it should, so treat any sudden electrical trouble as a reason to stop and arrange service.
Who's affected?
Spans 5 DL650 model years, all tied to the same alternator, generator, and regulator component.
| 2012 Suzuki DL650 | electrical system |
|---|---|
| 2013 Suzuki DL650 | electrical system |
| 2015 Suzuki DL650 | electrical system |
| 2014 Suzuki DL650 | electrical system |
| 2016 Suzuki DL650 | electrical system |
| Units affected | 8,613 |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific motorcycle is included.
What's the safety risk?
Stator wire shorting can keep the battery from charging. When battery power drops, the engine can stall, increasing the risk of a crash in traffic. If the motorcycle stalls or shows charging trouble, get out of traffic safely and call the dealer instead of continuing the ride. Repair is free at any franchised Suzuki dealer.
What should I do?
- Check your VIN to confirm your 2012-2016 Suzuki DL650 is included in this recall.
- Contact a franchised Suzuki dealer to schedule the free stator replacement that fixes the short-circuit risk and battery charging failure.
- Bring the recall notice if Suzuki mailed one. If not, reference recall number 16V878 when you call.
- Ride cautiously until the repair is complete. Watch for weak battery charging or engine stalling, and stop riding if the motorcycle stalls.
What happens at the repair
At the dealer, a Suzuki technician replaces the alternator stator covered by the recall. The stator is part of the motorcycle charging system. Replacing it addresses the short circuit risk in the stator wires described in campaign 16V878. The recall repair is available now, and the replacement parts and labor are free at a Suzuki dealer. Ask the service desk to confirm the campaign number when scheduling the repair.
Timeline
| December 6, 2016 | NHTSA published the recall |
|---|---|
| December 12, 2016 | Dealer notification began |
| December 12, 2016 | Dealer notification ended |
| December 19, 2016 | Interim owner notification (was planned for this date) |
| January 6, 2017 | Owner notification mailed |
Frequently asked questions
What is recall 16V878?
Recall 16V878 covers 8,613 2012-2016 Suzuki DL650 motorcycles with alternator stators that lack enough heat resistance. The stator wires can short circuit, stop the battery from charging properly, stall the engine, and increase crash risk. Suzuki dealers replace the stator for free.
What should I do if my 2012-2016 Suzuki DL650 is on this recall?
Check your VIN to confirm your specific motorcycle is included in recall 16V878. If it is, contact a franchised Suzuki dealer to schedule the stator replacement. Reference Suzuki recall number 2A67 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to repair recalled safety defects at no cost. Suzuki's remedy for recall 16V878 says dealers will replace the stator free of charge at a franchised Suzuki dealer.
Is it safe to ride my Suzuki DL650 before the repair?
The safety risk is an engine stall from a charging-system failure. In recall 16V878, a short circuit in the stator wires can stop the battery from charging properly, which can stall the engine and increase crash risk. Schedule the free stator replacement before relying on the motorcycle.
What if I bought my Suzuki DL650 used?
The free recall repair still applies. Federal recall law follows the vehicle, not the first owner. Check your VIN to confirm whether your specific DL650 is included, then contact a franchised Suzuki dealer and reference recall 16V878 or Suzuki recall number 2A67.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V878000 |
|---|---|
| Suzuki customer service | 1-714-572-1490 |
| NHTSA recall # | 16V878 |
| NHTSA recall # (full) | 16V878000 |
Source documents
-
Download Misc. Document (PDF) - Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →