MC27-04 – Damaged Spark Plugs May Cause Engine Stall – 2023-2024 Kawasaki ZX400S & ZX400P (2023 Ninja ZX-4RR KRT Edition, 2024 Ninja ZX-4R, & 4RR) Motorcycles

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March 21, 2024 NHTSA CAMPAIGN NUMBER: 24V221000

Damaged Spark Plugs May Cause Engine Stall

An engine stall increases the risk of a crash.

 

NHTSA Campaign Number: 24V221

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

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 1,579

 

Summary

Kawasaki Motor Corp., U.S.A. (KMC) is recalling certain 2023-2024 ZX400S and ZX400P (2023 Ninja ZX-4RR KRT Edition, 2024 Ninja ZX-4R, and 4RR) motorcycles. The spark plugs may have been damaged during the vehicle manufacturing process, which can result in unstable idling, hesitation, and engine stalling.

 

Remedy

Dealers will replace all four spark plugs, free of charge. The manufacturer has not yet provided a schedule for recall notification. Owners may contact KMC customer service at 1-866-802-9381. KMC’s number for this recall is MC27-04.

 

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

 


Chronology :

  • December 2023: Kawasaki Motors, Ltd (KML) received a report from its Chinese distributor subsidiary (KMSH) of several instances of rough idling. KMSH suspected that the cause was malfunctioning spark plugs. KML Quality Assurance Division started an investigation of the cause.
  • January 2024: Kawasaki’s spark plug supplier reported to KML that spark plugs were being cracked by an external force somehow.
  • February 2024: After investigating the manufacturing process for this model, KML determined that the spark plug tightening tool was tilted during installation, applying force laterally to the spark plugs and creating the opportunity for the spark plugs to be cracked during manufacture.
  • February 2024: KML reproduced this phenomenon in testing using cracked spark plugs, which revealed that not only rough idling, but stalling could also occur.
  • March 21, 2024:KML decided to initiate a recall campaign.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
KAWASAKI ZX400P 2023-2024
KAWASAKI ZX400S 2023-2024

 


3 Associated Documents

Defect Notice 573 Report

RCLRPT-24V221-2515.PDF 217.771KB

 


Recall Acknowledgement

RCAK-24V221-8490.pdf 695.38KB

 


Recall 573 Report – 3/22/24

RCLRPT-24V221-1662.PDF 217.766KB

 


Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V221&docType=RCL

 


 

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Last update on 2024-03-27 / Affiliate links / Images from Amazon Product Advertising API

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