NHTSA Complaint #11660383 — 2019 HONDA CBR600RR

I had the fuel pump recall (NHTSA ID 24V-113) performed on my 2019 Honda CBR600RR at a certified dealership. After the repair, I discovered multiple serious safety issues that made the motorcycle significantly more dangerous than it was before the recall: The fuel tank vent line was crushed under the tank during reassembly, completely blocking the vent system. This caused a vacuum lock that made the fuel cap impossible to open after riding, creating a risk of fuel starvation, fuel pump failure, or even tank deformation. The fuel level float arm was improperly installed and became jammed against an internal pipe inside the tank. The result is a fuel gauge stuck at “Full,” giving no indication of actual fuel level and preventing safe monitoring or refueling. When I contacted the dealership, they told me to ride the bike 30 miles back to them — despite the tank being sealed and the fuel level unknown. I also contacted Honda Powersports, who stated they have no responsibility and that only the dealer can address the issue, despite this being a federally mandated safety recall. I have not yet corrected the problem myself due to the serious safety implications and the need for proper accountability. The technician errors during this recall service introduced a more immediate and severe crash risk than the original defect the recall was intended to fix. Attached are photos showing the fuel level sensor float arm hung up on a hard pipe inside the tank, and the repair order from the dealership which performed the repair.