Honda two-wheeled, powered, off-road vehicles

The reports, as CPSC published them

1. Hospital admission

   Made Jun 30, 2026 · , sent to the company Jul 6, 2026 · , published by CPSC Jul 20, 2026

   The product, in the report: Its causing people to get hurt or killed

   Was riding a 2026 Honda Crf 450 in the field no bumps or nothing out of nowhere it caught the death wobble and trown me off and broke my collarbone

   Model

   Crf 450

   Bought from

   Currychainsaw

   Bought

   Mar 4, 2026

   Where

   Pembroke, North Carolina: Other

   Who was involved

   Age 20, Male

   The reporter’s relation to them

   Self

   As this report names them

   Brand Honda, made or sold by American Honda Motor Co., Inc.

   How badly, in CPSC’s words

   Injury, Hospital Admission

2. Emergency room

   Made Aug 9, 2024 · , sent to the company Aug 14, 2024 · , published by CPSC Aug 28, 2024

   The product, in the report: [REDACTED]

   I am writing to inform you of a serious incident involving the Honda CFR110 VIN # [REDACTED] that I purchased on February 10, 2023 On August 20,2023, my 11-year-old son was involved in a severe accident while riding the bike. The handlebar grip slipped off, causing him to lose control and fall. As a result of this accident, my son sustained multiple injuries, including: Three broken fingers on his right hand A broken right arm and elbow Bruises all over his body A concussion, which required specialist care A broken left collarbone Due to these injuries, my son missed three months of school and had to attend numerous doctor and follow-up appointments. He also had to wear a cast on his right side from his fingers to past his elbow for two months. Given the severity of his injuries and the emotional distress caused by this incident, I intend to file a lawsuit against your company for the physical and emotional damages my son has suffered. I urge you to take immediate action to address this issue and prevent further harm to other users. Please contact me at your earliest convenience to discuss this matter further. Sincerely, [REDACTED] Feel free to adjust the details as needed. If you need any further assistance or have any questions, please let me know.

   Model

   CRF 110

   Serial number

   [REDACTED]

   Bought from

   V1 Moto

   Bought

   Feb 10, 2023

   Where

   Houston, Texas: Mobile/Manufactured Home

   Who was involved

   Age 11, Male

   The reporter’s relation to them

   My Child

   As this report names them

   Brand Honda, made or sold by American Honda Motor Co., Inc.

   How badly, in CPSC’s words

   Injury, Emergency Department Treatment Received

3. No one hurt

   Made Apr 14, 2023 · , sent to the company Jun 6, 2023 · , published by CPSC Jun 21, 2023

   The product, in the report: 2016 Honda CRF450r

   On February 18, 2023, I brought In a Honda CRF450r to DuPage Honda Yamaha (Dealer) for a defective transmission countershaft fifth gear recall, in which the gear may break under certain riding conditions causing the transmission to seize. Unfortunately, while performing the service, the thread for the transmission oil drain bolt split. It is my understanding the Dealers service department contacted the Honda manufacturer (Honda) to cover the repair as a secondary claim to the recall. The repair would entail replacing the engine case and Its compromised parts. To this date, there has been no resolution to the recall or the engine case repair. I am disappointed because we have inconsistent statuses between Honda and the Dealers representatives. On February 28th, the Dealers service department notified me that Honda had approved the secondary warranty claim to repair and complete service over the recall. I just had to wait a couple more days to obtain my motorcycle at no cost. On March 2nd, I called the Dealer for a status of the motorcycle and was then told Honda contacted them the night before to notify them the secondary warranty claim was no longer approved. If not approved, although they were submitting supporting documentation to obtain approval, my estimated cost would be $930.On March 8th at approximately 12:46pm, the Dealer noted to me that an email had been sent to the attention of [REDACTED] at Honda with photos of the parts and notes of the problem, in which It would allow for the engines case repair to be covered by warranty. The Dealer also noted that per a previous conversation with Honda the day prior, Honda does not have a [REDACTED] In their department As such, the Dealer requested Honda to review their emails since all system records from the Dealer are no longer available. Due to a system failure, the Dealer lost all support and original records submitted. The Dealer noted to me that Honda would reach out to them with conclusion of the claim, and they would contact me thereafter. On March 8th at approximately 3:23pm, I called Honda at [REDACTED]. Honda noted to me that their case under phone# [REDACTED]/case # [REDACTED] Included no record of photography or email to review. They noted there Is no [REDACTED] who works In their department. They further noted they had communicated with the Dealer on March 7th and communicated their decision of not covering the secondary claim as they believe an incorrect bolt was used on the engines case. From their perspective, they would not be contacting the Dealer again. On March 9th, I called the Dealer, left a voicemail, and did not hear back on status of the motorcycle. On March 11th, I went to the Dealer In person due to lack of response. They noted they would contact Honda once again since they had not heard on final status to their claim. Per pictures taken by me on the day of my visit, the engine crank case appears cracked, which I did not leave the motorcycle in such condition and would require new parts. Neither party is taking responsibility for a correction to the motorcycle required for my safety. The motorcycle was given In good conditions. In my opinion, I should not be responsible for Incremental repair costs on this recall. Based on how this situation has transpired, I have no confidence that the issue was an incorrect bolt on the motorcycle as Honda notes. Who guarantees the error wasn’t due to the mechanic not using an impact gun? Who guarantees that if an impact gun was used, the Impact gun was positioned correctly or that no excessive torque was used? Who guarantees that the bolt was ever too tight If I was never consulted or notified of the Issue until the damage was caused and the Honda manufacturer was already contacted?

   Model

   2016 CRF450r

   Where

   Unspecified: Unspecified

   Who was involved

   Unspecified

   The reporter’s relation to them

   Unspecified

   As this report names them

   Brand Honda, made or sold by American Honda Motor Co., Inc.

   How badly, in CPSC’s words

   Incident, No Injury

4. Hurt, care not known

   Made Jan 12, 2021 · , sent to the company Feb 18, 2021 · , published by CPSC Mar 4, 2021

   The product, in the report: Honda CRF250R motocross off-road motorcycles

   Re: UNREASONABLE RISK OF SERIOUS INJURY OR DEATH CONCERNING HONDA CRF250R MULTIPLE YEAR MODELS AND OTHER DISPLACEMENT MOTOCROSS OFF-ROAD HONDA MOTORCYCLES AND DENSO STATORS DUE TO ELECTRICAL FAILURE AND SUDDEN UNINTENDED ENGINE SHUT OFF ENGINE FAILURE DURING OPERATION AND WHILE IN MOTION.

   I. REPORT AND COMPLAINT SUBMITTED IN ORDER TO PROTECT CONSUMERS AND OTHER RIDERS FROM FORESEEABLE FUTHER INJURIES OR DEATH DUE TO KNOWN UNSAFE AND UNREASONABLY DANGEROUS HONDA AND DENSO DEFECTIVE PRODUCTS.

   This Report and Complaint is respectfully submitted to the United State Consumer Product Safety Commission in order to prevent foreseeable further injuries and potential deaths due to known defective products put into the stream of commerce by Honda and Denso and sold to Americans countrywide and affecting certain motorcycles worldwide.

   II. AMERICAN HONDA MOTOR CO., INC., HONDA MOTOR CO., LTD., DENSO CORPORATION AND THE HONDA CRF250R. This Report and Complaint and attachment(s) concerns certain model years Honda CRF250R motocross off-road motorcycles manufactured by Honda Motor Co., LTD in Japan and sold in the United States by American Honda Motor Co., Inc., with stators incorporated thereto manufactured by Denso Corporation. The population of affected Honda off-road motocross motorcycles are unsafe and unreasonably dangerous to operate and must now be investigated, recalled and properly remedied.

   III. SUPERIOR COURT OF CALIFORNIA COUNTY OF LOS ANGELES UNLIMITED CIVIL CASE.

   In re and subsequent to the [REDACTED] [settled favorably for the Plaintiff]), we present facts that uncontrovertibly demonstrate the clear existence of product defects that make certain model year Honda CRF250R motorcycles unsafe and unreasonably dangerous to operate resulting in unreasonable risk of serious injury or death.

   American Honda Motor Co., Inc., Honda Motor Co., LTD., and Denso Corporation have known for years about the foregoing product defects but have failed to report or recall their defective unreasonably dangerous products.

   IV. SUDDEN UNINTENDED ENGINE SHUT OFF DUE TO PRODUCT DEFECT.

   The product defects contained within the 2014 and many other year model Honda CRF250Rs, because they can result in the motorcycle’s engine suddenly and unexpectedly turning off during operation and ceasing operation in its entirety while in motion (unintended engine shut off), which exposes children, retail end users and other riders to unreasonable risk of serious injury or death because the motorcycle’s engine can suddenly and unexpectedly stop running and operation without any indication it is about to fail.

   The failure of the engine to continue running when appropriate may cause loss of control, leading to motorcycle crashes and therefore significantly raises the risk of serious injury or death.

   V. REQUEST FOR INVESTIGATION OF HONDA AND DENSO; REQUEST FOR INVESTIGATION AND RECALL OF UNREASONABLY DANGEROUS PRODUCTS.

   This Report and Complaint are submitted to formally request investigation of Honda and Denso and recalls of the affected Honda CRF250R (and Honda CRF450R [and any other model using similar Denso stators]) off-road motocross motorcycle populations in the United States in order to reduce the unreasonable risk of serious injury or death to other unsuspecting operators. This Report and Complaint should be forwarded to your counterparts in Canada and Europe wherein Honda has marketed and sold its defective CRF250R off-road motocross motorcycles.

   This Report and Complaint concerns a 2014 model year Honda CRF250R incident off road motocross motorcycle, a similar brand new 2014 model year Honda CRF250R exemplar off-road motocross motorcycle, other similar models, and approximately five or more years-worth of production Honda CRF250R motorcycles.

   Multiple model years and multiple displacement off-road motorcycles are affected by the product defect(s) and should be recalled by the manufacturer.

   To our knowledge, Honda and Denso and their various business entities have not voluntarily recalled these products.

   Stator failures have occurred in the United States and Europe. Stator failures have occurred with racing teams.

   The manufacturer has subsequently improperly used or directed to be used, epoxy as a means to secure defective stator wires. Honda likes gluing together important electrical connections and Denso does not know whether their stators will be used on motorcycles with or without 12VDC batteries and the results thereof. Both are significant failures and embarrassments to Honda and Denso respectively.

   The use of epoxy to additionally secure defective stator wires is below the standard of care and not in accord with industry standards.

   Honda and Denso have actual knowledge of the product defects that form the basis of this Report and Complaint.

   Honda and Denso should provide the Consumer Product Safety Commission with all information, data and documents relevant to the matter in order to facilitate determination of the scope of the defective stator’s utilization in the population of motorcycles it has sold to the American public and worldwide. A thorough investigation by the CPSC will likely uncover the defects are both manufacturing and design defects.

   A recall of all affected Honda off-road motorcycles using defective Denso stators will help ensure no children or adults are seriously injured or killed as a result of Honda’s knowing and continued use of defective electrical components. VI. HONDA STATOR FAILURES AND UNINTENDED ENGINE SHUT OFF RESULTING IN ENGINE FAILURE AND SUBSEQUENT OPERATOR PARALYSIS.

   I was retained in order to look into a 2014 Honda CRF250R off-road motocross motorcycle, its sudden unintended engine shut off and crash, operated by a licensed professional rider, during practice, on a motorcycle closed-circuit dirt track.

   The facts of the case indicate the incident 2014 Honda CRF250R’s engine suddenly and unintentionally shut off during normal and foreseeable operation, resulting in a horrendous crash and subsequent rider paralysis. An objectively tragic outcome directly caused Honda’s defective product.

   As part of the case workup, we determined a copper wire in the motorcycle’s stator located within the engine of the incident motorcycle had failed, fractured and disconnected. The stator is made by Denso for Honda is at issue concerning these defective unreasonably dangerous off-road motocross motorcycles, please see infra.

   If a stator copper wire fractures the result is the engine shuts off (extremely fast, no prior warning) in under 4/10’s of a second. Stators are not generally considered wear items and are expected to last the life of most motorcycles.

   As general mechanical and operational propositions and industry standards, stator wires do not just become disconnected absent something more. The stator is internal to the motorcycle’s engine and it is not a component that can be damaged by merely operating and riding these machines.

   The crash of this 2014 Honda CRF250R off-road motocross motorcycle left the operator seriously injured resulting in paralysis and he is now permanently handicapped in a wheelchair for the rest of his life due to a particular defective Honda motorcycle.

   As a court qualified motorcycle expert in the field of motorcycles and other vehicles, I felt it necessary to report these defects and unsafe conditions present within the population of Honda off-road motocross motorcycles in order to protect other children and adults from being seriously injured or killed by these objectively defective Honda and Denso products.

   It is important these companies and products are now investigated and subsequently recalled in order to preclude another serious injury or potential death associated with these unreasonably dangerous and unsafe motorcycles. VII. THE 2014 HONDA CRF250R INCIDENT OFF-ROAD MOTOCROSS MOTORCYCLE. Image 001 was captured during an early non-destructive visual only inspection of the incident 2014 Honda CRF250R.

   The stator is an electrical component located within the motorcycle’s engine behind a left side metal engine cover. As the engine rotates, magnets are rotated, on a rotor or flywheel, around a set of copper windings and generate electrical current which then goes on to provide ignition and spark to the engine in order for the engine to run and continue running.

   If a stator copper wire becomes an open circuit (a wire breaks), the motorcycle’s stator will no longer output electricity properly. These off-road machines do not have a 12 VDC battery on board designed in. Therefore, if the stator’s electrical output is mechanically interrupted, the engine will almost immediately stop firing and will suddenly and unexpectedly stop running and shut off, potentially leading to a crash likely resulting in serious injury or death. VIII. THE DEFECTIVE HONDA AND DENSO STATOR. Image 002 is the actual incident Honda motorcycle’s Denso stator assembly minus its rotor.

   The connection of the copper winding is at issue and the wire that fractured and failed causing a serious motorcycle crash resulting in the operator’s paralysis can be seen above (and below next page with magnification) partially within its connector surrounded by solder. Image 003 is with magnification of the solder ball covering the copper wire and its crimp connector. Please notice the fracture and disconnect area are located around the outside diameter (and through the wire) of the copper wire in image 003. Obviously, this wire should not be in this fractured and disconnected improper condition absent a product defect.

   The fracture and disconnection of this wire caused an open circuit of the electrical circuit powering the ignition to occur.

   When power to the ignition is eliminated the motorcycle’s engine almost immediately shuts off, blink of an eye fast. We have tested exemplar stators and an exemplar 2014 Honda CRF250R off-road motocross motorcycle and produced video in which we purposefully interrupted the stator electrical output and measured the time in which ittakes for the engine to suddenly shut off during operation. Loss of engine power can cause a loss of vehicular control.

   When a motorcycle’s engine unexpectedly stops running and unintentionally suddenly shuts off, a motorcycle may become difficult, if not impossible, to control and may cause a crash resulting in serious injury or death.

   The [REDACTED] Ignition Switch Recalls present similar circumstances to the known defects regarding Honda and Denso products. Although the parts involved are different from the [REDACTED] automotive ignition key switch recall from 2014, the results are very similar in that much as if a [REDACTED] ignition fails and shuts off a motor vehicle’s engine a crash and serious injury or death can occur, the result of a failed Denso stator in a

   Honda off-road motocross motorcycle is the same in that sudden unintended engine shut off while in motion occurs which can cause a loss of vehicular control, a subsequent crash and result in serious injury or death to children, the retail consumer or other rider (other parts involved but same unsafe and unreasonably dangerous conditions and results).

   Additionally, the Honda CRF250R’s engine cannot be restarted after stator and therefore engine failure occurs. Once the stator failure occurs, the left side of the engine must be disassembled, a new stator added and engine reassembly, then the Honda CRF250R can be restarted and ridden.

   We are submitting attached herewith a metallurgical report from a co-expert concerning the metallurgical failure mode of the 2014 Honda CRF250R incident stator.

   VIII. THE COVER UP RE WHAT DID HONDA AND DENSO KNOW AND WHEN CONCERNING THE DEFECT WITHIN THE HONDA CRF250R ENGINE.

   It is clear both Honda and Denso knew of the problems and defects associated with their defective products for years but failed to voluntarily recall their defective products. Honda had actual knowledge of the product defect for a lengthy period of time and thus far to date has failed to do the right thing and failed to voluntarily recall their product(s).

   Honda’s supplier, Denso, failed to appreciate the potential results of wire failure within the stator assembly and did not properly understand what would happen if a failure were to occur. Concerning Honda’s supplier Denso, we do not know whether the defective manufacture of motorcycle stators has occurred for other brands and applications and whether defective stator assemblies have been supplied to other motorcycle manufacturers.

   It is conceivable the defective Denso stator issue is not limited to Honda motorcycles.

   It would be important for CPSC to determine whether defective Denso stators are in other brands of motorcycles, because the product defect may not be limited to Honda off-road motocross motorcycles and may affect other brands of motorcycles as well.

   Honda failed to take responsibility for the defect and blamed others for their product’s failure. Honda continued to market and sell the Honda CRF250R after and while having actual knowledge of the product defects present within their engines.

   The cover up of the product defect and failure to recall shocks the conscious and intentionally exposes children, retail end user consumers and other riders to unreasonable risk of serious injury or death.

   Please investigate Honda and Denso regarding this Report and Complaint and the issues herein, issue stop ride and stop sale orders on all affected model years and models of Honda off-road motocross motorcycles, pursue recalls and appropriate remedies for those affected by this unfortunate set of intentional circumstances. Let’s stop another tragedy before it occurs again. Thank you.

   Respectfully submitted. [REDACTED]

   Model

   CRF250R

   Where

   Unspecified: Unspecified

   Who was involved

   Male

   The reporter’s relation to them

   Unspecified

   As this report names them

   Brand Honda, made or sold by American Honda Motor Co., Inc.

   How badly, in CPSC’s words

   Injury, Level of care not known

CPSC’s disclaimer

Sources