Suzuki Motor USA has announced a recall of more than 3,000 motorcycles from its DR-Z4S/SM lineup due to incorrect assembly of the rear brake reservoir tank cap. The issue stems from screws that were not tightened to the proper torque during assembly, creating the risk of brake fluid leakage and reduced braking performance. The recall affects 1,431 units of the 2025 DR-Z4S, 1,554 units of the 2025 DR-Z4SM, and 18 early-production units of the 2026 DR-Z4S, for a total of 3,003 motorcycles.

The issue surfaced on November 10, 2025, when a foreign distributor reported a DR-Z4S with a loose reservoir cap screw and brake fluid leakage. Suzuki Motor Corporation launched an investigation, and by November 17 had found a vehicle with insufficient torque, prompting a suspension of shipments for both the DR-Z4S and DR-Z4SM. Subsequent checks on 171 held units revealed that 170 had improperly tightened screws. 

Models Affected

Further duplication tests uncovered the root cause: a torque application tool used in production had been incorrectly set, failing to account for torque loss. This meant screws were consistently tightened below specification. In the worst case, fluid levels could drop so low that the rear brake would lose effectiveness, extending stopping distances. Based on this finding, Suzuki initiated a safety recall campaign.

Riders are advised to monitor their rear brake reservoir closely and avoid riding if leakage is detected until repairs are completed. Visible brake fluid leakage around the reservoir cap seal may serve as a warning sign. 

Suzuki dealers will remedy the issue by tightening the reservoir cap screws to the correct torque specification and confirming proper brake pedal pressure. No new parts are required. Owner notifications are scheduled to begin on January 9, 2026. Suzuki has also filed a reimbursement plan for customers who may have already paid for related repairs. Owners may contact Suzuki customer service at 1-800-934-0934 and refer to the manufacturer recall # 3A09. Vehicle Identification Numbers (VINs) involved in this recall (NHTSA recall # 25V873) became searchable on NHTSA.gov on December 20, 2025.