Speed Display Failure – 2022 Kawasaki Ninja H2 SX SE (ZX1002R) Motorcycles

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December 9, 2022 NHTSA CAMPAIGN NUMBER: 22V913000

Speed Display Failure/FMVSS 123

Operating a motorcycle without a functioning speed display can increase the risk of a crash or injury.

 

NHTSA Campaign Number: 22V913

Manufacturer Kawasaki Motors Corp., U.S.A.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 200

 

Summary

Kawasaki Motors Corp., U.S.A. (KMC) is recalling certain 2022 Ninja H2 SX SE (ZX1002R) motorcycles. A software error in the multi-function meter may cause the motorcycle speed display to fail. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 123, “Motorcycle Controls and Displays.”

 

Remedy

Dealers will update the meter software, free of charge. Owner notification letters were mailed December 21, 2022. Owners may contact KMC customer service at 1-866-802-9381. KMC’s number for this recall is MC22-09.

 

Notes

Dealers will update the meter software, free of charge. Owner notification letters were mailed December 21, 2022. Owners may contact KMC customer service at 1-866-802-9381. KMC’s number for this recall is MC22-09.

 

Check for Kawasaki Recalls

 


Please be reminded of the following requirements:

We have received KMC’s proposed owner notification letter, and it is currently under review. You will be notified of any changes or concerns once our review is complete.

Copies of all notices, bulletins, dealer notifications, and other communications that relate to this recall, including a copy of the final owner notification letter and any subsequent owner follow-up notification letter(s), are required to be submitted to this office no later than 5 days after they are originally sent (if they are sent to more than one manufacturer, distributor, dealer, or purchaser/owner).

Under 49 U.S.C. § 30112(a), it is illegal for anyone, including a manufacturer, distributor, dealer, or retailer to sell an item of equipment or vehicle that fails to comply with all applicable Federal motor vehicle safety standards.

As stated in Part 573.7, submission of the first of eight consecutive quarterly status reports is required within one month after the close of the calendar quarter in which notification to purchasers occurs. Therefore, the first quarterly report will be due on, or before, 30 days after the close of the calendar quarter.

 


MC 22-09
December 20, 2022

2022 NINJA H2™ SX SE METER REPROGRAMMING

Eligible Units

Year Model Name Model Code
2022 NINJA H2™ SX SE ZX1002RNFNL

 

Subject

An improper control program in the vehicle speed display may cause the speed display to fail unexpectedly during use. Operating a motorcycle without a functioning speed display can increase the risk of a crash or injury.

 

Kawasaki Action

Initiate Campaign:
Kawasaki has initiated a Recall campaign to repair all eligible units. The repair consists of reprogramming the multi-function meter using KVCS.

Notify Registered Owners:
Kawasaki is sending a Recall letter to all registered owners of eligible units. A copy of the letter is printed on page 17 of this bulletin.

 

Dealer Action

Repair Eligible Units:
Repair all eligible units including sold units in the field and unsold units in your dealership inventory prior to delivery to the retail purchaser. It is the obligation of authorized Kawasaki retail Dealers to repair eligible units in Dealer’s possession prior to retail sale. Failure to comply with this obligation to repair all units eligible for Recall or FDM campaigns by the Dealer constitutes a breach of the Dealer Sales and Service Agreement. Refer to Service Policies bulletin SP 08-01. Refer to the Repair Procedure section of this bulletin for details.

IMPORTANT NOTE:

  • It’s the law! Under the U.S. National Highway Traffic Safety Administration (NHTSA), Federal Law 49 U.S.C. Section 30120(i) requires dealers to perform Recall repairs before delivering any vehicle affected by the Recall to a purchaser.

 

Repair Kit Part Number:
Kit 99999-0872 can only be ordered for eligible units. An eligible VIN will be required when ordering.
Order parts to complete the recall through K-Dealer as outlined in Service Bulletin SP15-03.

 

Kit, Meter Reprogramming, MC22-09
P/N 99999-0872

Ref.# Contents Qty
1 Data Link Cable 1

 

Reprogramming Equpment Required

This repair requires the following special tools and equipment.

Computer or Laptop [A] with the following:
-Current version of KVCS software (1.0.6.7 or higher)
-2 available USB A ports
-Internet connection
-Microsoft Edge browser

KVCI Device [B]

USB Cable, 57001-1844 [C]

Adapter Cable, 57001-1843 [D]

Adapter Cable, 57001-1880 [E]

Data Link Cable [F]
Order Repair Kit 99999-0872
VIN Required

 

Repair Procedure

Refer to the KVCS Connection Guide for detailed information related to cable connections.

Remove the both seats.

Connect cable 57001-1880 [E] to the red, fuel injection system coupler [R].

 

Connect cable 57001-1843 [D] to the KVCI Device [B].

Connect cable 57001-1843 [D] to the six pin connector [S] of cable 57001-1880 [E].

 

Connect the KVCI device [B] to the KVCS computer [A] with USB cable 57001-1844 [C].

 

Turn the ignition switch to the ON position without starting the engine.

 

Switch the KVCI device to the ON position.

 

IMPORTANT NOTE:
Close all internet browsers before proceeding to the next step.

 

Open the KVCS software.

Click on the ECU Reprogramming button.

 

Click on the Meter ECU button.

Select United States as the Region.

Enter your Dealer Code in ALL CAPS.

Enter your case sensitive KVCS password issued by Kawasaki (see bulletin ST21-02).

Click on the Login button.

 

Click on the Next button.

 

Click on the DL button.

 

Enter the odometer mileage.

Click on the Continue button.

 

Click on the OK button.

 

Enter activation code DAK910A.

Click on the Certification button.

 

Click on the OK button.

 

Click on the Download button.

Wait for the download to complete.

 

Click on the Next button once the download is complete.

 

CLOSE ALL INTERNET BROWSWERS BEFORE PROCEEDING TO THE NEXT STEP.

 

Click on the OK button then follow the instructions displayed on the screen to perform the meter reprogramming.

 

IMPORTANT NOTE:
Do not disconnect any of the previously connected cables.

 

Connect the Data Link Cable [F] (from repair kit 99999-0872) to the gray, meter communication connector [M].

Connect the USB A connector of the Data Link Cable [F] to a second USB port [P] on the computer.

 

IMPORTANT NOTE:
All cables must remain connected during the reprogramming procedure.

Computer or Laptop [A]

KVCI Device [B]

USB Cable, 57001-1844 [C]

Adapter Cable, 57001-1843 [D]

Adapter Cable, 57001-1880 [E]

Data Link Cable [F] from Repair Kit 99999-0872

 

Right click in the File name field.

 

Left click on Paste in the menu.

 

Click on the Open button.

 

IT IS NORMAL FOR THE METER ON THE VEHCILE TO SHUT DOWN AND START AGAIN DURING THE SOFTWARE UPDATE PROCESS.

 

Wait. 5 min Approx

 

Wait. 1 min Approx

 

The meter will display an ACC warning as shown. This is normal and will be cleared later in this bulletin.

 

The Results Report window will open when the reprogramming is complete.

 

Type MC22-09 in the Coment field.

Click on the Upload button.

 

Click on the Home button [H] once the reprogramming results report is complete.

IMPORTANT NOTE:
Failure to click the Home button [H] will prevent KVCS from performing any future reprogrammings. Be sure to finish the reprogramming by clicking the Home button.

 

Use the table below to verify the New Cal ID [C]. The correct new Cal ID indicates that reprogramming was successful.

Old Cal ID New Cal ID
49245-1885 49245-2253
49245-2137 49245-2254

★ If the New Cal ID is incorrect, repeat the reprogramming procedure, beginning on page 4.

RETURN TO THE KVCS HOME SCREEN TO CONTINUE.

 

Erase Stored FI ECU Service Codes

Click on the FI ECU button.

 

Click on the Diagnostics button.

 

Click on the Erase Stored Service Codes button to clear all FI ECU service codes.

 

Click on the OK button to confirm Clear all service codes.

Click on the OK button to confirm Erase finished.

 

Verify that the No service codes exist message [M] is displayed indicating that all FI ECU service codes have been cleared.

Close the FI – Fault Information window.

 

Erase Stored ABS ECU Service Codes

Click on the ABS ECU button.

 

Click on the Diagnostics button.

 

Click on the Erase Stored Service Codes button to clear all ABS ECU service codes.

 

Click on the OK button to confirm Clear all service codes.

Click on the OK button to confirm Erase finished.

 

Verify that the No service codes exist message [M] is displayed indicating that all ABS ECU service codes have been cleared.

Close the ABS – Fault Information window.

 

 

Erase Stored KECS ECU Service Codes

Click on the KECS ECU button.

 

Click on the Diagnostics button.

 

Click on the Erase Stored Service Codes button to clear all KECS ECU service codes.

 

Click on the OK button to confirm Clear all service codes.

Click on the OK button to confirm Erase finished.

 

Verify that the No service codes exist message [M] is displayed indicating that all KECS ECU service codes have been cleared.

Close the KECS – Fault Information window.

 

Close the KVCS software.

Close all internet browswers.

Turn the ignition switch to the OFF position then wait for 10 seconds.

Switch the KVCI device to the OFF position.

Disconnect all remaining cables from the vehicle.

Install the diagnostic connector covers.

Stow the diagnostic connectors.

Install both seats.

 

Repair Verification

Make a white paint mark [W] on the right hand side of the head tube above the last 6 digits of the VIN to serve as repair verification.

NOTE:
Repair verification is an essential part of the repair procedure. Along with the physical repair verification, check VIP (Vehicle Information Portal) in K-Dealer for other possible repair campaigns for eligible units.

 


Chronology :

  • June 2022: Kawasaki Motors, Ltd. (KML) received a report from Japanese distributor (KMJ) that “The meter screen became dark while running, then the boot up animation showed up due to restarting.”
  • June 2022: In reviewing the error log from the failed meter, it was revealed that some program, errors occurred during operation, causing the meter to restart.
  • July 2022: The occurrence of the same phenomenon was confirmed with the reliability test conducted by the supplier.
  • August-September 2022: Supplier continued to investigate the frequency and potential cause of this phenomenon.
  • October 2022: The supplier found that tasks to be processed were deleted due to a failure in the logic of the task processing program in the meter-unit, which caused the meter-unit to freeze. The meter would then restart.
  • December 2, 2022: KML decided to initiate a recall campaign.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
KAWASAKI ZX1002R 2022

 


10 Associated Documents

Noncompliance Notice 573 Report

RCLRPT-22V913-6741.PDF 212.491KB

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Recall Acknowledgement

RCAK-22V913-4336.pdf 646.939KB

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Recall 573 Report – December 14, 2022

RCLRPT-22V913-6146.PDF 217.222KB

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Recall 573 Report – December 14, 2022

RCLRPT-22V913-4317.PDF 217.222KB

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Remedy Instructions and TSB

RCRIT-22V913-6621.pdf 5560.543KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V913-2401.pdf 127.484KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V913-8220.PDF 211.138KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V913-4676.PDF 211.238KB

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Recall Quarterly Report #3, 2023-2

RCLQRT-22V913-6733.PDF 211.325KB

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Recall Quarterly Report – 10/02/2023

RCLQRT-22V913-6461.PDF 211.569KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V913&docType=RCL

 


 

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