NHTSA Complaint #10421498 — 1999 HONDA GL1500

A 1999 HONDA GOLDWING MOTORCYCLE WAS CONVERTED TO A TRIKE USING A CONVERSION KIT MANUFACTURED BY CHAMPION TRIKES, A DIVISION OF CHAMPION MOTORCYCLE ACCESSORIES INTERNATIONAL, INC FROM GARDEN GROVE CALIFORNIA. THE KIT USED WAS MANUFACTURED IN AUGUST OF 2006 WITH A SERIAL NUMBER OF 709268. THE SWING ARM ASSEMBLY IS THE MAIN CONNECTING MEMBER THAT JOINS THE TWO WHEEL REAR END TO THE FRONT END OF THE MOTORCYCLE. ON AUGUST 12, 2011 TWO CRACKS WERE FOUND IN THE SWING ARM STEEL AFFECTING BOTH SIDES OF THE ASSEMBLY. HAD THESE CRACKS BROKEN LOOSE AT HIGHWAY SPEEDS THE REAR END COULD SEPARATE FROM THE FRONT RESULTING IN SEVERE BODILY INJURY AND/OR DEATH OF THE RIDER AND PASSENGER. WHEN A CHAMPION REPRESENTATIVE WAS CONTACTED FOR ASSISTANCE IN REPAIR HE SAID IT WAS OUT OF THE THREE YEAR WARRANTY AND TOTALLY THE OWNERS RESPONSIBILITY TO REPAIR AT HIS OWN EXPENSE. THEY HAD NO INTEREST IN WHY IT HAD CRACKED OR DESIRE TO SEE THE FAILED PART. (THE REPAIR HAS BEEN MADE AND THE DEFECTIVE PART RETAINED.) THIS MOTORCYCLE HAS NOT BEEN WRECKED OR SUBJECTED TO ANY FORCE THAT CAUSED THE CRACKS TO OUR KNOWLEDGE. IT IS RIDDEN BY MY WIFE. I AM VERY CONCERNED THAT THERE MAY BE OTHER CHAMPION TRIKE CONVERSIONS ON THE ROAD WITH THE SAME CRACKS THAT ARE POTENTIAL ACCIDENTS WAITING TO HAPPEN. ACCORDING TO CHAMPION, THEY HAVE SOLD 17,000 OF THESE CONVERSIONS. THE CRACKS IN THE PART HAVE BEEN IDENTIFIED AS "STRESS CRACKS" BY THE DEALER THAT MADE THE REPAIR AND ALSO BY A FRIEND THAT WORKS WITH STEEL. THE CRACKS ARE LOCATED AT POINTS WHERE THE SWING ARM STEEL HAS BEEN DRILLED FOR A DRIVESHAFT PENETRATION ON ONE SIDE AND A BRAKE LINE PENETRATION ON THE OTHER. THE COST FOR THE REPAIR OF WHAT I BELIEVE WAS A MANUFACTURER'S DESIGN AND/OR STEEL DEFECT HAS COST US $1570.47 FOR THE PART INCLUDING SHIPPING AND $1088.16 FOR THE DISASSEMBLY, REMOVAL OF THE DEFECTIVE PART, AND REASSEMBLY OF THE REAR END. CHAMPION CHOSE NOT TO HELP IN ANY WAY. THE DEALER DID SELL ME THE PART AT HIS COST TO HELP. *TR