NHTSA Complaint #10910882 — 2003 YAMAHA XVS65

REAR DIFFERENTIAL PINION GEAR IS NOT LUBRICATED WITH GREASE DURING INITIAL ASSEMBLY. LUBRICATION OF THIS GEAR IS A COMMON PRACTICE IN THE MOTORCYCLE INDUSTRY. THIS OVERSIGHT CAUSES THE GEAR TO SLOWLY WEAR AWAY OVER TIME CAUSING CATASTROPHIC FAILURE OF THE DRIVETRAIN. IF THIS OCCURS IN A BUSY INTERSECTION SERIOUS INJURY OR DEATH MAY OCCUR. THIS IS A WELL KNOWN PROBLEM TO YAMAHA, YET THE COMPANY HAS FAILED TO CORRECT THIS DEFICIENCY OR MAKE A REPLACEMENT PART AVAILABLE. AT THE TIME WHEN MY PINION GEAR FAILED, I WAS IN MOTION AND THE SUDDEN LOSS OF FORWARD MOMENTUM PLACED ME IN THE PATH OF AN ONCOMING VEHICLE WHICH, FORTUNATELY, WAS ABLE TO SWERVE AND AVOID A COLLISION. THE ATTACHED PICTURE SHOWS THE DEFECTIVE PART, WHICH IS THE RUSTED PIECE IN THE CENTER OF THE GRAY COLORED HOUSING.