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July 26, 2023 NHTSA CAMPAIGN NUMBER: 23V515000
An engine stall can increase the risk of a crash.
NHTSA Campaign Number: 23V515
Manufacturer Kawasaki Motors Corp., U.S.A.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 991
Summary
Kawasaki Motors Corp., U.S.A. (KMC) is recalling certain 2023 ZX400SPFNL motorcycles. The alternator may fail due to a loose connection between the rotor and crank shaft, causing an engine stall.
Remedy
No remedy has been established at this time. The manufacturer has not yet provided a schedule for recall notification. 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.
Please be reminded of the following requirements:
You are required to submit a draft owner notification letter to this office no less than five days prior to mailing it to the customers. Also, 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).
Please be reminded that under 49 U.S.C. § 30112(a)(3), it is illegal for a manufacturer, to sell, offer for sale, import, or introduce or deliver into interstate commerce, a motor vehicle or item of motor vehicle equipment that contains a safety defect once the manufacturer has notified NHTSA about that safety defect. This prohibition does not apply once the motor vehicle or motor vehicle equipment has been remedied according to the manufacturer’s instructions.
As stated in 49 U.S.C. § 30118(f), submission of eight consecutive quarterly reports followed by three annual reports is required. As described in 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. The first of three consecutive annual status reports will be due on, or before, 1 year after the eighth quarterly report was submitted.
Chronology :
- April 2023: Kawasaki Motors, Ltd (KML) received a report from Kawasaki Motors Corp., U.S.A. (KMC) that one of these vehicles had problems starting. KML Quality Assurance Division started an investigation of the cause.
- June 2023: KML received a 2nd case report from Chinese distributor (KMSH) that “the engine cannot restart”.
- June 2023: KML inspected the vehicle which reported this 2nd incident of starting problems and found that the alternator rotor and the alternator rotor bolt were loose.
- July 2023: After investigating the manufacturing process for this model, KML determined that the cause of this problem was improper degreasing of the crank shaft prior to installation of the alternator rotor or improper tightening of the alternator rotor bolt during the manufacturing process.
- July 21, 2023:KML decided to initiate a recall campaign. Kawasaki Motors Corp., U.S.A. has not received any warranty claims, injuries or crashes related to this issue in the U.S. market.
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
KAWASAKI | ZX400 | 2023 |
5 Associated Documents
Recall Acknowledgement
RCAK-23V515-8306.pdf 647.031KB
Manufacturer Notices(to Dealers,etc)
Defect Notice 573 Report
RCLRPT-23V515-6993.PDF 212.474KB
Recall 573 Report – August 3, 2023
RCLRPT-23V515-3269.PDF 217.153KB
Recall 573 Report – August 4, 2023
RCLRPT-23V515-4321.PDF 217.232KB
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=23V515&docType=RCL
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SEOCONTENT-START
SALES For a complete listing of all current Kawasaki sales programs, please see our comprehensive eBinder on k-dealer.com. 23-20 MC National July 26, 2023 IMPORTANT STOP SALE NOTICE: STOP RETAIL SALES & DELIVERY OF 2023 NINJA® ZX™-4RR KRT EDITION REF: CODE: DATE: Year Model Name Model Code Eligibility 2023 NINJA ZX-4RR KRT EDITION ZX400SPFNL Verify using VIP in K-Dealer. Subject: Kawasaki is issuing a stop sale notice for model year 2023 NINJA ZX-4RR KRT EDITION. On eligible units, the alternator rotor could loosen and lead to alternator malfunction. What Dealers Must Do: • DISCONTINUE SALES OF 2023 NINJA ZX-4RR KRT EDITION MODELS IMMEDIATELY • CONTINUE PROCESSING AND SENDING PRODUCT REGISTRATION PAPERWORK FOR RECENT 2023 NINJA ZX-4RR KRT EDITION PURCHASERS Kawasaki expects to issue repair information to dealers in mid-to-late August of 2023. 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. Verify Stop Sale eligibility using VIP in K-Dealer. Vehicles outside this range are not affected by this Stop Sale Notice.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-515 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kawasaki Motors Corp., U.S.A. Submission Date : JUL 26, 2023 NHTSA Recall No. : 23V-515 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Kawasaki Motors Corp., U.S.A. Address : PO Box 25252 Santa Ana CA 92799-5252 Company phone : 949-770-0400 Population : Number of potentially involved : 991 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2023-2023 Kawasaki Motors, Ltd. ZX400SPFNL Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The affected vehicles containing the problem are certain 2023 ZX400S ( Kawasaki/ Ninja® ZX-4RR KRT Edition/991) models. The recall population was determined by the beginning and ending production date for the models affected. Production Dates : JAN 11, 2023 – MAR 29, 2023 VIN Range 1 : Begin : ML5ZXCS11PDA00082 End : ML5ZXCS10PDA01482 Not sequential Description of Defect : Description of the Defect : On certain eligible units, the alternator may malfunction because the connection between the alternator rotor and the crank shaft loosens. This connection loosens due to improper installation of the alternator rotor during the manufacturing process. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk that the engine may stall due to a loose alternator rotor. Description of the Cause : Error during installation of the alternator rotor and the alternator rotor bolt. Identification of Any Warning that can Occur : None Involved Components : Part 573 Safety Recall Report 23V-515 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : Kawasaki Motors Ltd. Address : 1-1, Kawasaki-cho, Akashi Hyogo Foreign States 673-8666 Country : Japan Chronology : NR Description of Remedy : Description of Remedy Program : NR How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : NR Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-515 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kawasaki Motors Corp., U.S.A. Submission Date : AUG 04, 2023 NHTSA Recall No. : 23V-515 Manufacturer Recall No. : MC23-06 Manufacturer Information : Manufacturer Name : Kawasaki Motors Corp., U.S.A. Address : PO Box 25252 Santa Ana CA 92799-5252 Company phone : 949-770-0400 Population : Number of potentially involved : 991 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2023-2023 Kawasaki Motors, Ltd. ZX400SPFNL Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The affected vehicles containing the problem are certain 2023 ZX400S ( Kawasaki/ Ninja® ZX-4RR KRT Edition/991) models. The recall population was determined by the beginning and ending production date for the models affected. Production Dates : JAN 11, 2023 – MAR 29, 2023 VIN Range 1 : Begin : ML5ZXCS11PDA00082 End : ML5ZXCS10PDA01482 Not sequential Description of Defect : Description of the Defect : On certain eligible units, the alternator may malfunction because the connection between the alternator rotor and the crank shaft loosens. This connection loosens due to improper installation of the alternator rotor during the manufacturing process. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk that the engine may stall due to a loose alternator rotor, increasing the risk of a crash. Description of the Cause : Error during installation of the alternator rotor and the alternator rotor bolt. Identification of Any Warning that can Occur : None Involved Components : Part 573 Safety Recall Report 23V-515 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : ROTOR Component Description : Alternator rotor (Flywheel) Component Part Number : 21007-0690 Supplier Identification : Component Manufacturer Name : Kawasaki Motors Ltd. Address : 1-1, Kawasaki-cho Akashi, Hyogo Foreign States 673-8666 Country : Japan Chronology : ・April 2023: Kawasaki Motors, Ltd (KML) received a report from Kawasaki Motors Corp., U.S.A. (KMC) that one of these vehicles had problems starting. KML Quality Assurance Division started an investigation of the cause. ・June 2023: KML received a 2nd case report from Chinese distributor (KMSH) that “the engine cannot restart”. ・June 2023: KML inspected the vehicle which reported this 2nd incident of starting problems and found that the alternator rotor and the alternator rotor bolt were loose. ・July 2023: After investigating the manufacturing process for this model, KML determined that the cause of this problem was improper degreasing of the crank shaft prior to installation of the alternator rotor or improper tightening of the alternator rotor bolt during the manufacturing process. ・July 21, 2023:KML decided to initiate a recall campaign. Kawasaki Motors Corp., U.S.A. has not received any warranty claims, injuries or crashes related to this issue in the U.S. market. Part 573 Safety Recall Report 23V-515 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : All eligible units require inspection of the alternator rotor. If the rotor is loose, the rotor will be re-affixed properly, and the alternator rotor bolt is tightened with increased torque. The plan of reimbursement has been described on the owner’s letter as follows: If you have experienced the failure described above prior to receiving this letter and have paid to have it corrected, you may be eligible for full or partial reimbursement for your documented cost of repair(s). To apply for reimbursement, please send copies of current owner and VIN information along with copies of repair orders and payment confirmation to the following address: Kawasaki Motors Corp., U.S.A. ATTN: Customer Care P.O. Box 25252 Santa Ana, California 92799-5252 How Remedy Component Differs from Recalled Component : Add a white mark on near the frame number. Identify How/When Recall Condition was Corrected in Production : From July 2023, the proper alternator rotor installation procedure has been followed and increased tightening torque has been applied to the alternator rotor bolt during the manufacturing process. Recall Schedule : Description of Recall Schedule : KMC will distribute both electronic and paper copies of a Recall Service bulletin to all Kawasaki motorcycle dealers. KMC will mail the owner notification letter via U.S.P.S. enclosed in an envelope with the statement “Important Recall Safety Information” printed on the outside of the envelope. Planned Dealer Notification Date : AUG 10, 2023 – AUG 10, 2023 Planned Owner Notification Date : AUG 14, 2023 – AUG 14, 2023 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-515 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kawasaki Motors Corp., U.S.A. Submission Date : AUG 03, 2023 NHTSA Recall No. : 23V-515 Manufacturer Recall No. : MC23-06 Manufacturer Information : Manufacturer Name : Kawasaki Motors Corp., U.S.A. Address : PO Box 25252 Santa Ana CA 92799-5252 Company phone : 949-770-0400 Population : Number of potentially involved : 991 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2023-2023 Kawasaki Motors, Ltd. ZX400SPFNL Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The affected vehicles containing the problem are certain 2023 ZX400S ( Kawasaki/ Ninja® ZX-4RR KRT Edition/991) models. The recall population was determined by the beginning and ending production date for the models affected. Production Dates : JAN 11, 2023 – MAR 29, 2023 VIN Range 1 : Begin : ML5ZXCS11PDA00082 End : ML5ZXCS10PDA01482 Not sequential Description of Defect : Description of the Defect : On certain eligible units, the alternator may malfunction because the connection between the alternator rotor and the crank shaft loosens. This connection loosens due to improper installation of the alternator rotor during the manufacturing process. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk that the engine may stall due to a loose alternator rotor, increasing the risk of a crash. Description of the Cause : Error during installation of the alternator rotor and the alternator rotor bolt. Identification of Any Warning that can Occur : None Involved Components : Part 573 Safety Recall Report 23V-515 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : ROTOR Component Description : Alternator rotor (Flywheel) Component Part Number : 21007-0690 Supplier Identification : Component Manufacturer Name : Kawasaki Motors Ltd. Address : 1-1, Kawasaki-cho Akashi, Hyogo Foreign States 673-8666 Country : Japan Chronology : ・April 2023: Kawasaki Motors, Ltd (KML) received a report from Kawasaki Motors Corp., U.S.A. (KMC) that one of these vehicles had problems starting. KML Quality Assurance Division started an investigation of the cause. ・June 2023: KML received a 2nd case report from Chinese distributor (KMSH) that “the engine cannot restart”. ・June 2023: KML inspected the vehicle which reported this 2nd incident of starting problems and found that the alternator rotor and the alternator rotor bolt were loose. ・July 2023: After investigating the manufacturing process for this model, KML determined that the cause of this problem was improper degreasing of the crank shaft prior to installation of the alternator rotor or improper tightening of the alternator rotor bolt during the manufacturing process. ・July 21, 2023:KML decided to initiate a recall campaign. Part 573 Safety Recall Report 23V-515 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : All eligible units require inspection of the alternator rotor. If the rotor is loose, the rotor will be re-affixed properly, and the alternator rotor bolt is tightened with increased torque. The plan of reimbursement has been described on the owner’s letter as follows: If you have experienced the failure described above prior to receiving this letter and have paid to have it corrected, you may be eligible for full or partial reimbursement for your documented cost of repair(s). To apply for reimbursement, please send copies of current owner and VIN information along with copies of repair orders and payment confirmation to the following address: Kawasaki Motors Corp., U.S.A. ATTN: Customer Care P.O. Box 25252 Santa Ana, California 92799-5252 How Remedy Component Differs from Recalled Component : Add a white mark on near the frame number. Identify How/When Recall Condition was Corrected in Production : From July 2023, the proper alternator rotor installation procedure has been followed and increased tightening torque has been applied to the alternator rotor bolt during the manufacturing process. Recall Schedule : Description of Recall Schedule : KMC will distribute both electronic and paper copies of a Recall Service bulletin to all Kawasaki motorcycle dealers. KMC will mail the owner notification letter via U.S.P.S. enclosed in an envelope with the statement “Important Recall Safety Information” printed on the outside of the envelope. Planned Dealer Notification Date : AUG 10, 2023 – AUG 10, 2023 Planned Owner Notification Date : AUG 14, 2023 – AUG 14, 2023 * NR – Not Reported
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