At the shop, Suzuki fuel-system issues have a recognizable signature. 69 documented complaints across 10 year-model entries from 2005 to 2008 is consistent with what we see come in. 2006 Suzuki GSX-R600 tops the list, but the pattern repeats across years. Multiple generations are affected. 3 crash reports on file. Not a high count, but the failure mode has put owners in the position to file. Average shop fix runs about $1,200 — not catastrophic, but it adds up over time. Check the fuel pump access cover for prior work. A vehicle on this list that already had a pump replacement is a vehicle to consider — the work is done.
ProblemsByVin SUZUKI / FUEL SYSTEM
10 model-year entries · 2005–2008
Suzuki fuel system problems
69 owner complaints filed with NHTSA against Suzuki vehicles for fuel system issues. 1 active recall campaign. See fuel system across all makes →
Complaints
69
Recalls
1
Year-models
10
Avg fix
$1,200
3crashes
1injury
Worst-affected Suzuki model-years for fuel system Top 10 by complaint volume
1 2 3 4 5 6 7 8 9 10
2006 Suzuki GSX-R600
15 complaints · ~$1,200 moderate
2007 Suzuki GSX-R600
13 complaints · ~$1,200 severe
2007 Suzuki GSX-R750
10 complaints · ~$1,200 severe
2007 Suzuki XL7
8 complaints · 1 recall · ~$1,200 moderate
2006 Suzuki GSX-R750
5 complaints · ~$1,200 moderate
2006 Suzuki VZR1800
5 complaints · ~$1,200 moderate
2005 Suzuki VL1500
4 complaints · ~$1,200 moderate
2008 Suzuki SX4
3 complaints · ~$1,200 moderate
2006 Suzuki Forenza
3 complaints · ~$1,200 moderate
2005 Suzuki Verona
3 complaints · ~$1,200 moderate
Active recalls — Suzuki fuel system 10 on file
On certain motorcycles, the fuel hose that connects the two metal fuel delivery pipes mounted on the throttle body may have been clamped at a location on the pipes that is not completely round, which could allow fuel leakage to occur
In the presence of an ignition source, leaked fuel can cause a fire, presenting the risk of injury or death.
Fix: Dealers will replace the fuel delivery pipe assembly free of charge. The recall began on april 6, 2007. Owners may contact Suzuki at 714-572-1490.
On certain scooters, the fuel pump retaining ring may have been improperly installed resulting in improper seating of the fuel pump retaining ring on the fuel tank due to misalignment of the threads
If the fuel pump retaining ring is not properly seated on the fuel tank, the fuel pump retaining ring could be deformed during normal expansion of the plastic fuel tank, resulting in insufficient sealing performance and fuel leakage. This could present a fire safety hazard and risk of injury or death.
Fix: Dealers will repair or replace the fuel pump retaining ring. The recall began on november 3, 2005. Owners may contact Suzuki at 714-572-1490.
Suzuki Motor of America, Inc
A cracked tank may leak fuel, increasing the risk of a fire.
Fix: Suzuki has sent owners an initial notification to inform them of the recall. When parts are available, a second notice will be mailed and dealers will install a cover over the opening near the suction pipe inlet, and relocate the suction filter. The fuel cap and fuel tank will also be replaced with improved parts. The recall began August 12, 2019. Owners may contact Suzuki customer service at 1-800-934-0934.
Suzuki Motor Of America, Inc
Negative pressure could cause the fuel tank to crack resulting in a fuel leak, increasing the risk of a fire.
Fix: Suzuki is in the process of notifying owners, and dealers will replace the evaporative canister vent line on the affected vehicles with a vent line that has a filter on the end. If the canister vent line is found to be obstructed by a spider web, the fuel tank will also be replaced. These repairs will be performed free of charge. The recall began on August 12, 2014. Owners may contact Suzuki customer service at 1-800-934-0934. Suzuki's number for this recall is VG.
On certain motorcycles, stress around the right front fuel tank mounting point can cause hairline fatigue cracks to form
In the presence of an ignition source, a fuel leak can result in a fire.
Fix: Dealers will inspect the fuel tank and install improved cushions that mount and support the fuel tank. Any fuel tanks that are found to have a crack will be replaced. If a tank is found to have a crack and a replacement tank is not available, fuel tank sealant will be applied to the tank as an interim repair. When the replacement tank becomes available, the owner will be contacted and a replacement tank will be installed. The recall began on february 3, 2006. Owners may contact Suzuki at 1-714-572-1490.
American Suzuki is recalling certain model year 2007 XL-7 vehicles originally sold or currently registered in Arizona, California, Nevada, and Texas; and manufactured June 13, 2006, through December 22, 2006
Fuel leakage in the presence of an ignition source may result in a fire.
Fix: American Suzuki will notify owners, and dealers will replace the fuel pump module, free of charge. An interim letter was mailed on March 7, 2013. Owners may contact American Suzuki Customer Relations at 1-800-934-0934.
On certain california-specification model motorcycles, repeated stress from vibration can cause a crack to form in the area where the liquid/vapor separator bracket is welded inside the fuel tank
Fuel leakage in the presence of an ignition source can result in a fire.
Fix: Dealers will replace the fuel tank free of charge. The recall began on february 3, 2006. Customers may contact american Suzuki at 714-572-1490.
Suzuki Motor of America, Inc
If the fuel tank breather hose is kinked, pressure may build inside the fuel tank and cause the tank to crack, resulting in a fuel leak, increasing the risk of a fire.
Fix: Suzuki will notify owners, and dealers will inspect and replace the fuel tank breather hose. If the existing breather hose was found to be kinked and obstructed, the fuel tank will also be replaced. These repairs will be performed free of charge. The recall began on January 8, 2016. Owners may contact Suzuki customer service number at 1-714-572-1490. Suzuki's number for this recall is 2A49.
Suzuki Motor USA, LLC (Suzuki) is recalling certain 2023-2025 Burgman 400 (AN400AM3-M5) scooters
A fuel leak in the presence of an ignition source increases the risk of fire.
Fix: Owners are advised that if they must ride the scooter before the safety recall repair has been completed, they should check the scooter for fuel leakage and proper operation as outlined in the "Inspection before riding" checklist in the owner's manual. Dealers will replace the fuel supply hose assembly and fuel vapor hose assembly with new parts, free of charge. Owner notification letters were mailed January 10, 2025. Owners may contact Suzuki customer service at 1-800-934-0934. Suzuki's number for this recall is 3A05.
Suzuki Motor of America, Inc
A fuel leak in the presence of an ignition source can increase the risk of a fire.
Fix: Suzuki will notify owners, and dealers will replace the fuel pump O-ring and the fuel tank inner vessel, free of charge. The recall began October 31, 2018. Owners may contact Suzuki customer service at 1-800-934-0934. Suzuki's numbers for this recall are 2A86-2A88.
Common questions
How many Suzuki fuel system complaints are on file with NHTSA?
69 complaints across 10 model-year entries from 2005 to 2008. 1 active recall campaigns cover fuel system issues across the Suzuki lineup.
Which Suzuki model has the most fuel system complaints?
The 2006 Suzuki GSX-R600 leads with 15 complaints in this category. Next: 2007 GSX-R600 (13) and 2007 GSX-R750 (10).
What does it cost to fix Suzuki fuel system problems?
Independent shops average $1,200 for fuel system repairs across the Suzuki lineup. Dealer pricing tends to run twenty to forty percent higher. Specific cost depends on the failure mode and parts availability.
Are there Suzuki fuel system recalls?
Yes — 10 active recall campaigns cover fuel system on Suzuki vehicles. Recall fixes are free regardless of mileage or warranty status. The list below shows current campaigns with their NHTSA numbers.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA) public records database.
Editorial commentary written by Shop Foreman, an independent contributor to ProblemsByVin
and not affiliated with Suzuki.
Severity ratings derive from reported crashes, fires, injuries, and fatalities on the NHTSA complaint and recall record.
Repair cost averages reflect independent-shop pricing and may differ in your area.