AFTER A 2 HOUR RIDE (90 MILES) ON HIGHWAYS AND LOCAL ROADS, I NOTICED THE PIN THAT HOLDS THE RIGHT SIDE HINGE (LOOKING AT THE MOTORCYCLE FROM THE REAR) OF THE HONDA ORIGINAL EQUIPMENT ACCESSORY "TOP BOX" CASE WAS PROTRUDING BY ABOUT 1 1/2" FROM ITS SOCKET. HAD IT MOVED ANY FURTHER, IT WOULD HAVE FALLEN OUT. HAD IT FALLEN OUT WHILE RIDING, THE TOP BOX CASE MIGHT HAVE BEEN BLOWN OPEN BY WIND FROM THE FRONT AND CAUSED A CRASH. I NOW CHECK ALL 6 HINGE PINS (2 ON THE TOP CASE AND 2 EACH ON THE SIDE PANNIERS) EVERY TIME I MOUNT THE BIKE. I FIND THE RIGHT TOP CASE PIN FREQUENTLY HAS SLIPPED OUT BY 1/4" ON A SHORT RIDE, AND I PUSH IT BACK IN WITH MY KEY. ALL 6 PINS ON THE TOP CASE AND 2 PANNIERS ARE IDENTICAL IN DESIGN. I WORRY THAT THE DESIGN OF ALL 6 PINS IS DEFECTIVE, MAY FAIL AND LEAD TO A SERIOUS ACCIDENT. I REPORTED THE PROBLEM TO MY HONDA DEALER WHO SUGGESTED I "FIX" IT MYSELF WITH SOME KIND OF ADHESIVE CAULK. I REPORTED THE PROBLEM TO HONDA ITSELF WHO SAID THE 1 PIN MAY POSSIBLY BE COVERED UNDER WARRANTY AND THEY "MAY" REPLACE THE TOP BOX. IF THEY REPLACE THE TOP BOX, THAT WOULD BE NICE, BUT, STILL, I WORRY THE PIN DESIGN ITSELF IS DEFECTIVE AND THAT THE OTHER PINS ON THE PANNIERS MAY FAIL TOO. I SHOULD NOT HAVE TO DO A SAFETY CHECK EVERY 25-50 MILES, YET, THAT CURRENTLY SEEMS TO BE NECESSARY. THE COMPANY SHOULD COME UP WITH A SOLUTION AND HAVE THEIR DEALERS IMPLEMENT IT FOR ALL PINS ON ALL ACCESSORY CASES FOR THEIR CB500XAE MOTORCYCLES. THIS SEEMS TO BE A SIMPLE PROBLEM WITH A SIMPLE POSSIBLE FIX (SOME SORT OF SEALANT/CLOSURE), BUT THE RISK OF A POTENTIALLY TRAGIC OUTCOME SEEMS SIGNIFICANT.
NHTSA ODI 10782174