Engine Stall While Riding – 2015-2023 Kawasaki Motorcycles

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December 9, 2022 NHTSA CAMPAIGN NUMBER: 22V912000

Engine Stall While Riding

An engine stall while riding can increase the risk of a crash or injury.

 

NHTSA Campaign Number: 22V912

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

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 3,172

 

Summary

Kawasaki Motors Corp., U.S.A. (KMC) is recalling certain 2015-2018 ZX1000, 2018 ZX1002A, ZX1002B, 2019-2021 ZX1002D, 2019-2022 ZX1002J, 2020-2023 ZR1000K, 2021-2022 ZR1000L, 2022 ZX1002R, and 2023 ZR1002L (Ninja H2, Ninja H2 Carbon, Ninja H2 SX, Ninja H2 SX SE, Ninja H2 SX SE+, Z H2, and Z H2 SE) motorcycles. Please see the attached model information chart for a detailed list of model codes, names and years. The plunger in the camshaft chain tensioner may lock, which can result in an engine stall while riding.

 

Remedy

Dealers will replace the camshaft chain tensioner, free of charge. Owner notification letters were mailed December 21, 2022. Owners may contact KMC customer service at 1-866-802-9381.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check for Kawasaki Recalls

 


REF: 22-22 MC
CODE: National
DATE: December 9, 2022

STOP RETAIL SALES & DELIVERY OF 2015~2023 Z H2, Z H2 SE, NINJA H2™, NINJA H2™R, NINJA H2™CARBON, NINJA H2™SX, NINJA H2™SX SE & NINJA H2™SX SE+

Year Model Name Model Code Eligibility
2015 NINJA H2 NINJA H2R ZX1000NFFL ZX1000PFF Verify using VIP in K-Dealer.
2016 NINJA H2 NINJA H2R ZX1000NGFL ZX1000PGF
2017 NINJA H2

NINJA H2 CARBON

NINJA H2 R

ZX1000XHFL

ZX1000XHFAL

ZX1000YHF

2018 NINJA H2

NINJA H2 CARBON

NINJA H2 R

NINJA H2 SX

NINJA H2 SX SE

ZX1000XJFL

ZX1000XJFAL

ZX1000YJF

ZX1002AJF, ZX1002AJFL

ZX1002BJF, ZX1002BJFL

2019 NINJA H2

NINJA H2 CARBON

NINJA H2 SX SE+

ZX1002JKFL

ZX1002JKFAL

ZX1002DKF, ZX1002DKFL

2020 NINJA H2

NINJA H2 CARBON

NINJA H2 R

NINJA H2 SX SE+

Z H2

ZX1002JLFL

ZX1002JLFAL

ZX1000YLF

ZX1002DLF, ZX1002DLFL

ZR1000KLF , ZR1000KLFB, ZR1000KLFL

2021 NINJA H2

NINJA H2 CARBON

NINJA H2 R

NINJA H2 SX SE+

Z H2

Z H2 SE

ZX1002JMFNL

ZX1002JMANL

ZX1000YMFNN

ZX1002DMFNL ZR1000KMFNL

ZR1000LMFNL

2022 NINJA H2

NINJA H2 CARBON

NINJA H2 R

NINJA H2 SX SE

Z H2

Z H2 SE

ZX1002JNFNL

ZX1002JNANL

ZX1000YNFNN

ZX1002RNFNL

ZR1000KNFAL

ZR1000LNFNL

2023 Z H2

Z H2 SE

ZR1000KPFAL ZR1000LPFNL

Verify Stop Sale eligibility using VIP in K-Dealer. Vehicles outside this range are not affected by this Stop Sale Notice.

 

Subject:

Kawasaki is issuing a stop sale notice for model year 2015~2023 Z H2, Z H2 SE, Ninja H2, Ninja H2 R, Ninja H2 Carbon, Ninja H2 SX, Ninja H2 SX SE & Ninja H2 SX SE+ models.

On eligible units, the plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts. Continuous use in this condition can result in loss of engine power during use.

What Dealers Must Do:

  • DISCONTINUE SALES OF 2015~2023 Z H2, Z H2 SE, NINJA H2, NINJA H2 R, NINJA H2 CARBON, NINJA H2 SX, NINJA H2 SX SE & NINJA H2 SX SE+ MODELS
  • CONTINUE PROCESSING AND SENDING PRODUCT REGISTRATION PAPERWORK FOR RECENT 2015~2023 Z H2, Z H2 SE, NINJA H2, NINJA H2 R, NINJA H2 CARBON,

NINJA H2 SX, NINJA H2 SX SE & NINJA H2 SX SE+ PURCHASERS

Kawasaki expects to issue repair information to dealers in mid-December of 2022. Owners of eligible units will be notified to contact an authorized Kawasaki motorcycle dealership to schedule an appointment to complete the repairs.

We apologize for any inconvenience experienced and are working toward a resolution of this matter as quickly as possible.

KAWASAKI MOTORS CORP., U.S.A.

 


MC 22-08
December 20, 2022

RECALL

Eligible Units

Yr Model Name Model Code
2015 NINJA H2

NINJA H2 R*

ZX1000NFFL ZX1000PFF*
2016 NINJA H2

NINJA H2 R*

ZX1000NGFL ZX1000PGF*
2017 NINJA H2

NINJA H2 CARBON

NINJA H2 R*

ZX1000XHFL

ZX1000XHFAL

ZX1000YHF*

2018 NINJA H2

NINJA H2 CARBON

NINJA H2 R*

NINJA H2 SX

NINJA H2 SX SE

ZX1000XJFL

ZX1000XJFAL

ZX1000YJF*

ZX1002AJF, ZX1002AJFL

ZX1002BJF, ZX1002BJFL

2019 NINJA H2

NINJA H2 CARBON

NINJA H2 SX SE+

ZX1002JKFL

ZX1002JKFAL

ZX1002DKF, ZX1002DKFL

2020 NINJA H2

NINJA H2 CARBON

NINJA H2 R*

NINJA H2 SX SE+

Z H2

ZX1002JLFL

ZX1002JLFAL

ZX1000YLF*

ZX1002DLF, ZX1002DLFL

ZR1000KLF , ZR1000KLFB, ZR1000KLFL

2021 NINJA H2

NINJA H2 CARBON

NINJA H2 R*

NINJA H2 SX SE+

Z H2

Z H2 SE

ZX1002JMFNL

ZX1002JMANL

ZX1000YMFNN*

ZX1002DMFNL ZR1000KMFNL

ZR1000LMFNL

2022 NINJA H2

NINJA H2 CARBON

NINJA H2 R*

NINJA H2 SX SE

Z H2

Z H2 SE

ZX1002JNFNL

ZX1002JNANL

ZX1000YNFNN*

ZX1002RNFNL

ZR1000KNFAL

ZR1000LNFNL

2023 Z H2

Z H2 SE

ZR1000KPFAL ZR1000LPFNL

*NINJA H2 R models covered under U.S. Consumer Product Safety Comission (CPSC) recall.

 

Subject

The plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts, which can result in an engine stall while riding. An engine stall while riding can increase the risk of a crash or injury. Our records indicate that you have purchased one of these units.

 

Kawasaki Action

Initiate Campaign:
Kawasaki has initiated a Recall campaign to repair all eligible units. The repair consists of replacing the camshaft chain tensioner.

Notify Registered Owners:
Kawasaki is sending a Recall letter to all registered owners of eligible units. A copy of the letter is printed on pages 5 and 6 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.

 

Parts Information

Repair Kit Part Number:
Kit 99999-0851 must be installed on all eligible units.
Order parts to complete the recall through K-Dealer as outlined in Service Bulletin SP15-03.

 

Kit, Chain Tensioner, MC22-08
P/N 99999-0851

Ref.# Contents Qty
1 Tensioner 1
2 Gasket, Tensioner 1

 

Repair Procedure

Refer to the applicable service manual for detailed information related to parts removal and installation.

NOTICE

This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.

When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in “Camshaft Chain Tensioner Installation.”

Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves.

  • Remove and retain camshaft chain tensioner mounting bolts [A].
  • Remove and discard camshaft chain tensioner [B].

 

  • Verify that stopper [A] is in groove [B] of push rod [C] before installing the tensioner.

IMPORTANT NOTE:

  • Be careful not to fit the snap ring [D] into the groove [B] (see images below).

 

  • Replace the gasket [A] with the new one from the repair kit.
  • Install the tensioner so that the plug [B] faces upward.
  • Tighten the camshaft chain tensioner mounting bolts to 89 in·lb (1.0 kgf·m, 10 N·m).

IMPORTANT NOTE:

  • When installing the tensioner, if the bolts don’t engage the cylinder head, the cam timing may be off. Remove the tensioner and check the cam timing then repeat the cam chain tensioner installation.

 

Extend Tensioner Pushrod

  • Press the starter switch quickly enough to turn the engine over but not long enough to start the engine. This will extend the tensioner pushrod against the camshaft chain.

 

Repair Verification

The new camshaft chain tensioner stamped with identification number 0120 will 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 of Defect / Noncompliance Determination

Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision:

  • November 2020: Kawasaki Motors, Ltd. (KML) received a report of abnormal engine noise on a vehicle from its Japanese distributor (KMJ). Upon inspection of the vehicle, KML discovered that the camshaft chain tensioner was locked.
  • November 2020: KML asked the supplier of the camshaft chain tensioner to inspect the failed part and report back. The supplier found no abnormalities and reported that there may have been a maintenance issue on the failed unit. The supplier reported to KML that it did not expect further issues with the part.
  • March – June 2021: KML received two additional reports of abnormal engine noise from KMJ, but none from other markets.
  •  September 2021: KML received a report that a vehicle lost power from KMJ. No accident or injuries were reported.
  • September 2021: KML Quality Assurance department shared these reports with KML Research & Development department and the supplier, then re-opened its investigation into this issue.
  • November 2021: As a result of the in-house investigation KML discovered that certain components of the camshaft chain tensioner varied dimensionally between units, though each was within the tolerance specified by KML for the component. However, KML did not know whether these variances between units were creating the problem.
  • February 2022 – September 2022: KML and the supplier continued to test the camshaft chain tensioner to replicate a lock up, first by manually compressing the tensioner, and then during engine operation. KML could not successfully replicate a lock up of the camshaft chain tensioner during engine operation.
  • October 2022: After an additional report of lost engine power from KMJ, KML began to look for a solution to this issue, though it still had not determined for certain that the variances between parts were the cause of the issue.
  • November 2022: KML decided to use a cam chain tensioner from a different model, which does not have this issue, on these models to eliminate this issue.
  • December 2, 2022: KML decided to initiate a recall campaign on these models to ensure that this issue does not occur on vehicles already in the field.

 


21 Affected Products

Vehicles

MAKE MODEL YEAR
KAWASAKI ZR1000K 2020-2023
KAWASAKI ZR1000L 2021-2022
KAWASAKI ZR1002L 2023
KAWASAKI ZX1000 2015-2018
KAWASAKI ZX1002A 2018
KAWASAKI ZX1002B 2018
KAWASAKI ZX1002D 2019-2021
KAWASAKI ZX1002J 2019-2022
KAWASAKI ZX1002R 2022

 


14 Associated Documents

Recall 573 Report – December 14, 2022

RCLRPT-22V912-5524.PDF 214.03KB

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Chronology Report

RMISC-22V912-3014.pdf 74.363KB

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Attachment A- Model Information

RMISC-22V912-2425.pdf 81.279KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V912-6714.pdf 37.32KB

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Defect Notice 573 Report

RCLRPT-22V912-2934.PDF 212.795KB

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Recall Acknowledgement

RCAK-22V912-8924.pdf 645.594KB

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Recall 573 Report – December 15, 2022

RCLRPT-22V912-5523.PDF 214.049KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V912-7757.pdf 129.814KB

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Recall 573 Report – December 27, 2022

RCLRPT-22V912-5643.PDF 214.068KB

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Remedy Instructions and TSB

RCRIT-22V912-4524.pdf 623.067KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V912-3991.PDF 211.123KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V912-1091.PDF 211.223KB

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Recall Quarterly Report #3, 2023-2

RCLQRT-22V912-8858.PDF 211.312KB

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Recall Quarterly Report – 10/02/2023

RCLQRT-22V912-1420.PDF 211.558KB

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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=22V912&docType=RCL

 


 

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