- Approximately 3,003 motorcycles affected, according to Suzuki 100 percent of the affected production batch
- All DR Z400 models from the 2025 model year and early 2026 models prior to November 14, 2025
- Recall concerns the mounting of the rear brake reservoir
According to Suzuki Motor USA, a problem with the assembly of the rear brake system has been identified in certain Suzuki DR Z400S and DR Z400SM models. Specifically, this concerns the screws used to secure the rear master cylinder reservoir. These are said not to have been tightened to the specified torque during the production process.
Cause and possible consequences of the defect
According to Suzuki, if the affected screws are not tightened correctly, brake fluid may leak. As a result, the rear brake may no longer function as intended. This can increase the risk of accidents and injuries. In addition, leaking brake fluid can damage components and paintwork if it gets onto unsuitable areas.
Suzuki cites visible brake fluid on the rear master cylinder cover or on the reservoir itself as a possible indication of the problem. A simple visual inspection can therefore provide initial signs.
Affected models and production periods
According to the manufacturer, all models of the Suzuki DR-Z400S and Suzuki DR-Z400SM from the 2025 model year are affected by the recall. This also includes motorcycles from the 2026 model year, provided they were produced before November 14, 2025.
Suzuki estimates that a total of approximately 3,003 motorcycles in the US are affected. According to internal documents, this corresponds to the entire relevant production volume.
Investigation and measures at the plant
Suzuki states that it has been investigating the matter since November 2025. The cause was ultimately identified as a tool with an incorrect torque setting that was used in the production process. From November 18, 2025, an additional control process was introduced to ensure that the screws are fitted with the correct tightening torque. Motorcycles produced after this date should therefore no longer be affected.
Information for dealers and customers
According to Suzuki, the dealer network in the US was informed of the recall on December 17, 2025. Registered vehicle owners are to be notified around January 9, 2025. Affected owners are asked to contact an authorized Suzuki dealer. There, an inspection will be carried out and, if necessary, the recall work will be performed free of charge.
In addition, Suzuki customer service is available to answer questions at 1 800 934 0934, as is the US National Highway Traffic Safety Administration. The latter can be reached by phone at 1 888 327 4236 or online via the agency’s official website.
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