MC20-02 – Damaged Air Suction Valves May Cause Fire – 2019-2020 Kawasaki Ninja ZX-10R, Ninja ZX-10R ABS, & Ninja ZX-10R ABS KRT Edition Motorcycles

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May 27, 2020 NHTSA CAMPAIGN NUMBER: 20V307000

Damaged Air Suction Valves May Cause Fire

Damaged air suction valves may allow high temperature exhaust gas to blow back through and melt surrounding parts, increasing the risk of a fire.

 

NHTSA Campaign Number: 20V307

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

Components ENGINE AND ENGINE COOLING, ELECTRICAL SYSTEM

Potential Number of Units Affected 1,529

 

Summary

Kawasaki Motors Corp., U.S.A. (Kawasaki) is recalling certain 2019-2020 NINJA ZX-10R, NINJA ZX-10R ABS, and NINJA ZX-10R ABS KRT EDITION motorcycles. The engine control unit (ECU) programming may cause the engine to backfire when the quick shift function is used under high engine load, possibly resulting in damage to the air suction valves.

 

Remedy

Kawasaki will notify owners, and dealers will reprogram the ECU and inspect the air suction valves and surrounding parts, replacing them as necessary. All repairs will be performed free of charge. This recall began June 8, 2020. Owners may contact Kawasaki customer service at 1-866-802-9381. Kawasaki’s number for this recall is MC20-02.

 

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.safercar.gov.

 

Check for Kawasaki Recalls

 


SERVICE

MC 20-02
June 5, 2020

TITLE: ENGINE BACKFIRE

RECALL

THIS BULLETIN IS OF THE HIGHEST PRIORITY AND MUST BE ACTED UPON IMMEDIATELY TO ENSURE CUSTOMER SAFETY.

 

Eligibility

Eligible Units

Year Model Model Codes
2019 NINJA® ZX™-10R ABS

NINJA ZX-10R ABS KRT Edition

NINJA ZX-10R ABS KRT Edition

NINJA ZX-10R ABS

NINJA ZX-10R

NINJA ZX-10R KRT Edition

NINJA ZX-10R KRT Edition

NINJA ZX-10R

NINJA ZX-10RR

ZX1002EKF

ZX1002EKFA

ZX1002EKFAL

ZX1002EKFL

ZX1002FKF

ZX1002FKFA

ZX1002FKFAL

ZX1002FKFL

ZX1002GKFL

2020 NINJA ZX-10R ABS

NINJA ZX-10R ABS KRT Edition

NINJA ZX-10R ABS

NINJA ZX-10R KRT Edition

NINJA ZX-10R KRT Edition

ZX1002ELF

ZX1002ELFAL

ZX1002ELFL

ZX1002FLFA

ZX1002FLFAL

 

Verify eligibility using VIP in K-Dealer before starting the repair.

Please check VIP (Vehicle Information Portal) in K-Dealer for other possible repair campaigns for eligible units.

 

Subject

On affected units, the engine could backfire while shifting under high engine loads when KQS (Kawasaki Quick Shifter) is activated, potentially resulting in damage to the air suction valve(s). Continued use could result in additional damage to surrounding parts caused by blow back of high temperature exhaust gas and creating the potential for a fire.

 

Kawasaki Action

Initiate Campaign:

Kawasaki has initiated a Recall campaign to repair all eligible units. The repair consists of reprogramming the ECU and replacing the air suction valve(s). A physical inspection of the area around the air suction valve assembly must also be carried out and repairs completed if required.

 

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 21 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.

 

Document Completed Repairs:

Federal law requires manufacturers to maintain accurate follow-up records on repairs performed on eligible units. Dealers MUST submit a Warranty Claim for each repair. Refer to the Warranty Information section of this bulletin for details.

 

NOTE:

  • If you fail to submit a Warranty Claim for a new unit that is subsequently sold and registered, the new owner will receive the Recall letter requesting the return of the vehicle to you for repair.

 

Submit Product Registration:

Submit the product registration to Kawasaki via K-Dealer immediately after retail sale of any eligible unit. Be sure to supply the correct customer name and mailing address. Kawasaki uses the product registration information for customer notification. Also, if you know that the customer has moved, please submit a Customer Update via K-Dealer.

 

Parts Information

Kit, Reed Valve, MC20-02 P/N 99999-0766  
Ref Contents Qty
1 Bolt 4
2 Valve 2

 

Repair Kit Part Number:

Install repair parts only on vehicles that have been ridden. Unsold units that have not been ridden do not need repair parts

Order parts to complete the Recall through K-Dealer as outlined in Service Bulletin SP15-03.

 

REPAIRS REQUIRED BASED ON RIDING HISTORY OF VEHICLE

  • If the unit has never been ridden, perform the ECU reprogramming only.
  • If the unit has been ridden, perform the ECU reprogramming, valve replacement and inspection.

 

Special Tool Requirements

This repair procedure requires the following special tools

  • KVCS Kit
  • Computer or laptop with KVCS installed
  • Internet connection

 

ECU Reprogramming Sequence

Reprogramming consists of four steps. All steps must be completed to successfully reprogram the ECU:

  • Saving the ECU Data
  • Downloading the reprogramming data from the server
  • Writing the Program data to the ECU
  • Reporting the Reprogramming to the Server

 

ECU Reprogramming

ECU REPROGRAMMING VIDEO TUTORIAL:

  • PLEASE WATCH THIS VIDEO PRIOR TO REPROGRAMMING THE ECU.
  • OPEN THIS BULLETIN IN K-DEALER TO CLICK ON THE BUTTON TO VIEW THE VIDEO

 

IMPORTANT NOTES:

  • The vehicle’s battery voltage must be greater than 10.5 Volts to perform this procedure. Do not attempt to reprogram the ECU if the battery voltage is below 10.5 Volts. Charge the battery as required.
  • This procedure requires an internet connection and a computer with KVCS installed.

 

Save Vehicle ECU Data

  • Connect cable 57001-1843 to the KVCI device.

 

NOTE:

    • Only the KVCI device and the vehicle will be connected to each other while saving the vehicle ECU data.

 

  • Confirm the power switch on the KVCI device to the OFF position.
  • Connect KVCI device to vehicle’s white, six pin coupler, using cable 57001-1843.
  • Turn the ignition switch ON but do not start the vehicle.
  • Slide the power switch on the KVCI device to the ON position.
  • Wait 10 seconds for the KVCI device to power up and connect with the vehicle ECU
  • Press the A button to open the Main Menu on the KVCI device.

 

The Main Menu appears.

  • Press the A button to select Reflash.
  • Press the A button again.
    • The Battery Terminal Voltage screen will appear.
      • If the battery voltage is below 10.5 V, stop this procedure. Charge the battery and begin at step one again.
      • If the battery voltage is greater than 10.5 V, proceed to the next step.
  • Press the A button again when the Menu screen appears with Save vehicle ECU data as the option.
  • Verify that the message Downloading Vehicle ECU Data is displayed.
    • If the “Downloading Vechicle ECU Data” screen does not appear shut down and start over.
  • Confirm the downloaded vehicle ECU data on the Completion of Vehicle ECU Data screen.
ECU # 21175-XXXX
Cal ID 49245-XXXX
VIN FRAME NUMBER

 

    • If the ECU VIN is different from the FRAME VIN, use the FRAME VIN in the warranty request.

 

Slide the mode switch of KVCI device to the OFF position.

  • Turn the ignition switch to the OFF position and wait ten seconds before proceding to the next step,

 

NOTICE
Turn the ignition switch of the vehicle to the OFF position, wait for around 10 seconds, and then release the connection between the KVCI device and the vehicle. If you release the connection while power is still being supplied the KVCI device may fail

 

  • Remove KVCI device from the vehicle.

 

Download Reprogramming Data

  • Connect KVCI device to your KVCS equipped computer with USB cable 57001-1844.

 

NOTE:

    • Only the KVCI device and the computer running KVCS will be connected to each other while downloading the reprogramming data from the server.

 

  • Slide the power switch on the KVCI device to the ON position.
  • Launch the KVCS program from the laptop or PC.

 

  • Select ECU Reflash.

 

  • Confirm ECU data in the “Vehicle ECU Data” field.
  • Click on the Search Reprogramming Data button.

 

  • Select United States as the Region.
  • Enter your KVCS Dealer Code and Password then click the Login (Call Kawasaki Dealer Care at (800) 854-3800 if you do not have your dealer code and password.)

 

  • Verify the reprogramming data for the vehicle based on the following tables:

 

ZX1002E/F

ECU P/N CalID Note
21175-1426 49245-1757 USA
21175-1427 49245-1758 L Model

 

ZX1002G

ECU P/N CalID Note
21175-1434 49245-1766 USA
21175-1435 49245-1767 L Model

 

  • Click on the DL button to download the vehicle data.

 

  • When the download is complete, the Confirm Download screen will appear.
  • Enter the VIN on the vehicle frame in the VIN field.
  • Click on the Continue button.

 

  • The Proceed to VIN Verification message will appear if the correct VIN is entered.
  • Click on the OK button.
  • Proceed to page 8 of this bulletin and resume at the Activation Code step.

 

The following screens will only appear if the VIN was entered incorrectly or the wrong VIN was entered. Proceed to ACTIVATION CODE on page 8 if the VIN is correct.

  • If VIN is not entered or VIN format is Incorrect, error message is displayed. Please enter VIN stamped on the vehicle frame and click Continue again.

 

  • If VIN entered does not match with ECU VIN, error message is displayed. If entered VIN is mistake, please enter correct VIN stamped on the vehicle frame and click Verify again.

 

  • If VIN entered is correct, please click VIN entered is correct. Reprogramming can be done even if the VINs do not match.

 

  • If the message The VIN entered does not match the ECU VIN. Proceed to download the reprogramming data with the VIN entered? is displayed, click on the OK button.

 

Activation Code

  • A new screen will appear that has a field to enter the Activation Code.
  • Enter Activation Code DAJ883A then click on the Certification (Activation code DAJ883A is used for all vehicles for this step.)

 

  • After the checkmark symbol appears to the right of the activation code, click on the Download button to begin downloading the reprogramming data from the server.

 

  • A confirmation dialog box will appear asking if you would like to authenticate the Activation Code. Click on the OK button.

 

  • A progress bar will indicate the progress of the download. It may take a few seconds before the progress bar begins to display in green.
  • When the download is complete, the bar will disappear and information of reprogramming data will be displayed in the Reprogramming Data field.

 

  • Click on the button next to the image of the KVCI device.

 

  • Slide the power switch on the KVCI device to the OFF position.
  • Disconnect the KVCI device from the PC.

 

Write Reprogramming Data to ECU

  • Connect cable 57001-1843 to the KVCI device.

 

NOTE:

    • Only the KVCI device and the vehicle will be connected to each other while saving the vehicle ECU data.

 

  • Slide the power switch on the KVCI device to the OFF position.

 

  • Connect KVCI device to vehicle’s white, six pin coupler, using cable 57001-1843.

 

  • Turn the ignition switch ON but do not start the vehicle.

 

  • Slide the power switch on the KVCI device to the ON position and wait approximately 10 seconds for the device to connect with vehicle ECU.
  • Press the A button on the KVCI device.

 

  • The Battery Terminal Voltage screen will appear.
  • Press the A button to open the KVCI Menu.

 

  • The KVCI Menu is displayed.

 

  • Use the down arrow key on the KVCI device to select Reprogram Vehicle ECU.
  • Press the button.

 

  • Confirm the downloaded Reprogramming data for rewriting.
  • Press the button.
Name Description
ECU P/No 21175-XXXX
Cal ID 49245-XXXX
Remarks Displayed reference information such as contents of program.
VIN Frame Number

 

ZX1002E/F

ECU P/N CalID Remarks
21175-1426 49245-1757 USA
21175-1427 49245-1758 L Model

 

ZX1002G

ECU P/N CalID Remarks
21175-1434 49245-1766 USA
21175-1435 49245-1767 L Model

 

  • During the reprogramming, the Reprogamming in Progress status is displayed as a percentage and the green light under the symbol on the KVCI device illuminates.

 

NOTE:

    • The ECU will not be recognized during reprogramming and the warning lamp will be blinking. It will return to its original display state when the reprogramming is complete.

 

 

    • If you receive a message on the KVCI device with the message “There is a possibility that the previous reprogramming did not finish properly. Would you like to run the recovery process?” you will need to perform the recovery process. Select YES then press the A button to perform the recovery process. Otherwise, proceed to the next step below.

 

IMPORTANT NOTE:

    • WAIT FOR THE Completion of Reprogramming SCREEN TO APPEAR BEFORE TURNNING OFF THE KVCI DEVICE OR THE VEHICLE IGNITION SWITCH. TURNING THE POWER OFF TOO SOON WILL RESULT IN INCOMPLETE REPROGRAMMING.

 

  • Slide the mode switch of Kawasaki Smart VCI to the OFF position only when the Completion of Reprogramming screen is displayed.

 

NOTICE
Turn the ignition switch of the vehicle to the OFF position, wait for around 10 seconds, and then release the connection between Kawasaki Smart VCI and the vehicle. If you release the connection while power is still being supplied, Kawasaki Smart VCI may fail.

 

  • Turn the ignition switch to the OFF position.

 

  • Remove Kawasaki Smart VCI from the vehicle.
  • Start the vehicle and verify that the engine light is not flashing.

 

Reporting the Vehicle ECU Reprogramming to the Server

  • Launch the KVCS software.

 

NOTE:

    • Only the KVCI device and the computer running KVCS will be connected to each other while downloading the reprogramming data from the server.

 

  • Select ECU Reflash.
  • Connect the KVCI device to the computer with the USB cable.
  • Slide the power KVCI device power switch to the ON position.

 

  • On the KVCS software select Report on the Reprogramming Completion Report
    • If the Unreported 0 Items is displayed on the Reprogramming Completion Report column, ECU reprogramming is not finished completely. Please perform the reprogramming process again. By selecting Search History, the reported vehicle ECU data lists will be displayed.
    • If the Unreported 1 Items is displayed on the Reprogramming Completion Report column, ECU reprogramming is complete.
  • Click on the Report button only if Unreported 1 Items is displayed.

 

  • Enter MC20-02 in the Remarks field

 

  • Click on the Report button to report the unreported item.

 

  • Click on the OK button on the Would you like to report the results? screen.

 

  • Click on the button at the bottom of the page displaying “Reported to server”.

 

  • Confirm Unreported 0 Items is displayed on the Reprogramming Completion Report column.
  • If Unreported 1 item is displayed on the Reprogramming Completion Report, Reporting is not finished completely. Please report the download vehicle ECU Data to the server again.

 

NOTE:

    • If there are unreported vehicle ECU data, you cannot download another reprogramming data. After reporting the downloaded vehicle ECU data to the server, please download other unit’s reprograming data and write the reprograming data.

 

  • Slide the mode switch of KVCI device to the OFF position.
  • Remove KVCI device from the PC.

 

ECU REPROGRAMMING IS NOW COMPLETE

  • Proceed to the Warranty Section on page 19 if the vehicle has never been ridden.
  • Proceed to the Remove & Replace Reed Valve section on page 15 if the vehcle has been ridden.

 

Remove & Replace Reed Valves

REMOVE & REPLACE REED VALVES ONLY ON VEHICLES THAT HAVE BEEN RIDDEN.

  • Remove the seat, tail cover, tank cover and fuel tank as outlined in service manual 99832-0011-01.

Remove Air Cleaner Housing

  • Disconnect:

-Secondary Fuel Hose

-Intake Air Temp Sensor Connector [A]

-IMU Connector [B]

-Secondary Fuel Injector Connectors [C]

  • Remove :

-Turn signal relay [D],

-Radiator fan relay [E]

-ESD (Electronic Steering Damper) ECU [F]

  • Free the clamps [G] from the air cleaner housing.
  • Remove Connector Bracket [A]
  • Slide the clamps.
  • Disconnect:

-Air Cleaner Drain Hose [B]

-Breather Hose [C]

  • Loosen air cleaner housing clamp bolts [D].
  • Remove bolts [A].
  • Free bracket [B].
  • Remove bolt [C] and washer.
  • Disconnect the air switching valve hose [A].
  • Remove the air cleaner housing.

 

Remove Air Switching Valve

NOTICE
Never drop the air switching valve especially on a hard surface. Such a shock to the air switching valve can damage it.

 

  • Disconnect connector [A].
  • Disconnect hoses [B] from the air suction valve covers.
  • Remove the air switching valve [C]

 

Remove Air Suction Valve

  • Open clamps [A].
  • Roll up the front side of the heat insulation rubber plate [B].
  • Remove and discard air suction valve cover bolts [A].
  • Remove and retain air suction valve cover [B]
  • Repeat for valve on the other side of the engine.
  • Remove and discard air suction valves from both sides of the engine.
  • Install new air suction valves [A] on both sides of the engine with the reed stopper facing downwards and the white mark [B] toward the rear.
  • Install the air suction valve covers [A] on the air suction valve [B].
  • Remove the locking agent from the air suction valve cover bolt holes with a thread chaser or a tap
  • Install new air suction valve cover bolts [C], and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
Description Part No.
Air Suction Valve [A] Call Dealer Care for Authorization to Replace Parts
Tube [B]
Tube [C]
Tube [D]

 

Remove Air Suction Valve

  • Inspect Parts around the Air Switching Valve and hoses.
  • Visually inspect Air Switching Valve [A] and Tubes [B], [C], [D], to include inner and outer areas of the tube.
    • If any of these parts have heat or fire damage, replace them with new parts.
Description Part No.
Radiator Assembly Call Dealer Care for Authorization to Replace Parts
Front Brake Switch
Right-Housing-Assy-Control
Coil-Assembly-Ignition
Heat Insulation Rubber Plate
Harness
Other Parts not Listed

 

  • Visually inspect the following parts:

-Radiator Fan Motor Lead Connector [A],

-Front Brake Switch Lead Connector [B],

-Right Housing Assy Control Lead Connector [C],

-Ignition Coil [D],

-Harness, Heat Insulation Rubber Plate…etc

  • If any of these parts have heat or fire damage, replace them with new parts.
Description Part No.
Air Cleaner Housing Call Dealer Care for Authorization to Replace Parts
Pad
Secondary Fuel Injector

 

  • Visually inspect the following for damage:

-Front side of Air Cleaner Housing [A]

-installation point of air switching valve hose [B]

-Secondary Fuel Injector [C] for any damage.

  • If any of these parts have heat or fire damage, replace them with new parts.

 

Air Switching Valve Installation

  • Install air switching valve [A] with hose [B] as shown.

-Front [C]

-Left Side View [D]

-Yellow Paint [E]

 

Air Cleaner Housing Installation

  • Be sure to install the pad [A].
  • Install the air cleaner housing clamps [A] so that their bolt heads [B] face inward.
  • Install the air cleaner housing [C] to the throttle body assy.

-Collar [D]

-Damper [E]

-Washer [F]

  • Be sure the air cleaner housing is inserted to the throttle body assy securely.
  • Be sure the hoses are routed correctly and properly installed.
  • Tighten air cleaner housing clamp bolts [B] & [G] to 18 in·lb (0.20 kgf·m, 2.0 N·m).
  • Run the leads and hoses correctly. (See Cable, Wire, and Hose Routing)

-Rubber Cover (Wrap the turn signal relay  and radiator fan relay.) [1]

-Turn Signal Relay and Radiator Fan Relay [2]

-Clamps (Hold the secondary fuel injector  connector. Install them to the air cleaner  housing.) [3]

-IMU [4]

-Fuel Tank Breather Hose [5]

-Clamp (Hold the main harness. Close it  after installing the fuel tank breather hose.) [6]

-Run the fuel tank breather hose in outside  of the main harness. [7]

-Run the fuel tank drain hose to the inside of  the breather hose. Run it in front of the fuel  hose. [8]

-Clamp (Hold the fuel hose. After holding the  hose with the clamp, take the hose forward  and install the fuel tank.) [9] -Breather Hose [10]

-Fuel Tank Drain Hose [11]

-Fuel Hose [12]

-Clamp (Hold the secondary fuel injector  leads and fuel tank breather hose. Position  the hose joint under the clamp. Run the  fuel tank breather hose in front of the main  harness.) [13]

-Position the corrugate tube in the clamp.  [14]

-Run the fuel tank breather hose between  the rubber boot and air cleaner housing. [15]

-US and L Models [16]

  • Install removed parts.
  • Start the engine to verify that the engine light is not flashing after completing all repairs.

 

CALL KAWASAKI DEALER CARE AT (800) 854-3800 FOR AUTHORIZATION OF ADDITIONAL TIME REQUIRED TO COMPLETE REMOVAL AND REPLACEMENT OF DAMAGED PARTS.

 

Warranty Information

This is a safety Recall campaign. Repair is authorized regardless of ownership or warranty status.

Repairs MUST BE PERFORMED IMMEDIATELY ON ALL ELIGIBLE UNITS in the field and during initial assembly and preparation if the inspection reveals a damaged brake hose or sensor wire.

See the Warranty Policies and Procedures Manual (claim type 3 information) for detailed instructions when submitting the Warranty Claim.

Reprogram Only Reprogram & Replace Reed Valves Reprogram & Replace Reed Valves & Replace Heat Damaged Parts
Job Code 22527 22528 22529
Flat Rate Time 0.3 1.4 1.4
Claim Type 3 3 3
Part Number 99999-0766 99999-0766 99999-0766
Description Kit, Reed Valve MC20-02 Kit, Reed Valve MC20-02 Kit, Reed Valve MC20-02
Quantity 0 1 1
Additional Parts N/A N/A Call Dealer Care at

(800) 854-3800 for additional time

authorization to remove and replace heat damaged parts

 

Repair Verification

  • Make a white paint mark on the rear edge of the ECU found under the tool kit as shown below 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.

 

NOTE:

  • ECU removed for clarity only. Do not remove from vehicle.

 


2019 & 2020 NINJA® ZX™-10R, 10RR, 10R ABS, & 10R ABS, & 10R KRT EDITION, ABS KRT EDITION ENGINE BACKFIRE

IMPORTANT SAFETY RECALL

NHTSA RECALL NO. 20V-307

 

Dear Kawasaki Motorcycle Owner:

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Kawasaki Motors Corp., U.S.A., has decided that a defect which relates to motor vehicle safety exists in certain 2019 & 2020 NINJA® ZX™-10R, 10RR, 10R ABS, & 10R KRT EDITION, ABS KRT EDITION models.

 

The reason for this notice:

On affected units, the engine could backfire while shifting under high engine loads when KQS (Kawasaki Quick Shifter) is activated, potentially resulting in damage to the air suction valve(s). Continued use could result in additional damage to surrounding parts caused by blow back of high temperature exhaust gas and creating the potential for a fire. Our records indicate that you have purchased one of these units.

 

What Kawasaki and your dealer will do:

Kawasaki has authorized your dealer to reprogram the ECU (Engine Control Unit) on your motorcycle and replace the air suction valve(s). A physical inspection of the area around the air suction valve assembly will also be carried out and repairs completed if required. All repairs will be performed free of charge.  The actual repair will take up to one and a half hours but may take longer due to scheduling at the dealership and the time needed to obtain required parts.

 

What should you do to ensure your safety?

Please call your Kawasaki dealer to schedule an appointment to have your motorcycle inspected and repaired as required. Please have your Vehicle Identification Number (VIN) ready when calling. To locate the nearest authorized Kawasaki motorcycle dealer, please visit www.kawasaki.com and click on the “LOCATE DEALER” link.

 

If you need help:

If you have questions or concerns that your dealer is not able to resolve, please contact Kawasaki Customer Care at (866) 8029381 (toll-free) between 7:00 a.m. and 4:00 p.m. PT Monday through Friday. Please have your Vehicle Identification Number ready when calling.

If your dealer fails or is unable to remedy this defect without charge within a reasonable amount of time (60 days after your first attempt to obtain remedy), you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration,

1200 New Jersey Ave. S.E., Washington, D.C. 20590, or call the toll-free Vehicle Safety Hotline at 1(888) 327-4236 (TTY: 1-800-4249153); or go to https://www.safercar.gov.

 

If you received this notice in error:

Our records indicate you are the current owner of the motorcycle described in this letter. If you no longer have the vehicle described in this letter, please help us to update our records at www.kawasaki.com by clicking on “OWNER CENTER => OWNER SUPPORT => UPDATE OWNER INFO” or by calling Kawasaki toll free at (866) 802-9381. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 

Reimbursement:

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

 

Please note the following conditions for reimbursement:

Claims may be excluded if proper documentation is not included. Current owner and VIN information along with copies of repair orders and payment confirmation must be provided.

We are sorry for any inconvenience this may cause, but we have taken this action in the interest of your safety and your continued satisfaction with your Kawasaki motorcycle.

Sincerely,

Kawasaki Motors Corp., U.S.A.

 


6 Affected Products

Vehicles

MAKE MODEL YEAR
KAWASAKI ZX1002E 2019-2020
KAWASAKI ZX1002F 2019-2020
KAWASAKI ZX1002G 2019-2020

 


9 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-20V307-1666.pdf 624.254KB

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V307-0417.PDF 211.142KB

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Recall 573 Report – Amendment 1

RCLRPT-20V307-1429.PDF 218.614KB

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Remedy Instructions and TSB

RCRIT-20V307-7196.pdf 6465.034KB

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Defect Notice 573 Report

RCLRPT-20V307-9877.PDF 218.545KB

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Recall Acknowledgement

RCAK-20V307-2151.pdf 313.51KB

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Recall Quarterly Report #2, 2020-3

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Recall Quarterly Report #3, 2020-4

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Recall Quarterly Report #4, 2021-1

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V307&docType=RCL

 


 

Bestseller No. 1
Motorcycle System Diagnostic Test Measurement Tools OBDII Motorcycle Fault Code Readers Scan Tools Motorcycle Code Reader Scanner Fit for Yamaha 2/3/4P,Kawasaki 4-6P,Honda 4P,OBDII
  • 🏍️【System Diagnosis Features】The Motocycle diagnostic tool Support engine / ABS / Tire pressure / Anti-theft and other systems, It can quickly read and clear diagnostic trouble codes, view freeze frame, display data stream and do active tests, get vehicle information, You are allowed to perform a complete and deep detection for your motorcycles, rather than send it directly to repair shop, very suitable for diyers.
  • 🏍️【Easy To Use】 Code Readers Scan Tools is a handheld motorcycle diagnostic tool for mainstream motorcycle brands and can help technicians diagnose problems faster and make repairs. This tool has functions such as voltage detection, multi-language selection, and unit switching. It has a clear interface and is easy to operate. It is a good helper for motorcycle maintenance.
  • 🏍️【Wide Compatibility】Motorcycle Fault Code Readers support the diagnosis of Asian, European and American multi-brand motorcycles, M3-A is suitable for motorcycles of Yamaha, Honda, Kawasaki and OBD2, Supports 11 languages, You can switch the language you need anytime.
  • 🏍️【Portable and Convenient】The motorcycle diagnostic requires no Internet connection or setup, and with a lightweight body that can be operated with one hand, you can take it anywhere and use it very conveniently.
  • 🏍️【Free Software Upgrade】Connect the device to the computer and wait for the device to be recognized by the computer. After the recognition is successful, a new drive symbol will appear on the computer. Open this and replace the “DIAGNOSE" folder in the drive with the downloaded “DIAGNOSE" upgrade folder, and then power on again. The updated files can be obtained by contacting the customer service.
Bestseller No. 2
TOPDON TopScan Motorcycle Diagnostic Tool, Wireless Motorcycle OBD2 Scanner Fits for Harley, Ducati, BMW, All Systems Motorbike Scanner Tool with Hot Reset Functioan, Data Stream
  • Bi-Directional Control, Target The Problems Easily: TopScan Moto's bi-directional feature allows you to send commands directly from your smartphone to your vehicle's ECU for active testing. Helps you differentiate between software and hardware issues, quickly narrowing down the problem and reducing diagnostic time for mechanics and can help DIY users locate faults more easily!
  • Wireless Diagnostics, Pack light anytime, anywhere: Designed for use on the go, transforming your smartphone into a diagnostic tool. the TopScan Moto's compact size and Bluetooth 5.0 compatibility provide seamless wireless diagnostics. Easily carry it with you and solve problems on the go.
  • Full System Diagnosis: TopScan Moto Covering engine, ABS, smart key, entertainment systems and more, it ensures a thorough analysis for overhauling 20 internal systems. It can quickly read and clear troubleshooting codes, view freeze frames, display data streams and perform active tests, get vehicle information, and know the condition of your vehicle anytime, anywhere.
  • Moto Reset Function, Better Care of Your Car: Dive into maintenance functions, including oil maintenance resets, service indicator adjustments, and idle speed tweaks. Comprehensive diagnostics, maintenance insights, and on-the-go convenience so you can work on your motorcycle, anytime, anywhere.
  • Rider Full Vehicle Pass: Whether you are an off-road rider, a cruiser, a superbike rider or an adventure rider, it has your back. This amazing motorcycle diagnostic tool supports Ducati, BMW, Harley, Bombardier, Indian and more. Supports 12 languages, You can switch the language you need anytime.
Bestseller No. 3
Original TopDiag M100 Pro Motorcycle Scanner Professional Diagnostic Tool for Motorcycle (Standard Version)
  • 【Topdiag M100 pro Hand-Held Operation】: Jdiag m100 pro motorcycle scanner is hand-held operation, easy to use, simplo and flexible, fast troubleshooting.
  • 【Topdiag M100 Pro Widely Used For Motorcycle Repair】:Suitable for motorcycle maintenance technicians andpersonal vehicle maintenance and repair.
  • 【Multiple Battery Test Methods】Jdiag m100 pro motorcycle scanner: Multiple test methods for more professional testing of car batteries.
  • 【Support Multi-languages】:English,Traditional Chinese, Viotnamese, Indonesian, Thai, Spain;Turkey, Portugel, French, Khmer.
  • 【Jdiag m100 pro motorcycle scanner support Motorcycle list】: Hartford, Aeon, Honda, SYM, Yamaha,Suzuki,Kymco,Kawasaki,Piaggio,PGO,KTM, etc
Bestseller No. 4
OBDPROG MOTO 100 Motorcycle Diagnostic Scan Tool, Full System Scanner for Harley Honda Yamaha Victory Indian Polaris Brp, Engine ABS TPMS Auto Scan Code Reader, Oil Light Reset, 5.0 Touch Screen
  • 💯OBDPROG MOTO 100 Diagnostic Scan Tool Compatible with a wide range of Harley Davidson motorcycles, including Touring, Dyna, Softail, Sportster, Touring CVO, and VRSC V-Rod and more.
  • 💯OBDPROG MOTO 100 Diagnostic Scan Tool Compatible with Polaris motorcycles, including RANGER, ATV, Snow, RZR, Slingshot, Commercial, LEV, ACE, General, and Generic and more.
  • 🍻[Compatible with over 1000 models and makes] For Indian motorcycles (Chieftain, Scout, Scout Sixty, Scout Bobber, Springfield, and more), For BRP motorcycles (Commander, DS, Defender, Maverick, Outlander, Renegade, Traxter, Spyder, Adventure, Boondocker, and more), For Victory motorcycles (Vision, High-Ball, Cross Country, Cross Roads, and more), For Yamaha motorcycles, and Honda motorcycles. Equipped with a 5.0-inch touch screen and offers easy WiFi updates during the first year at no additional cost. After the first year, a yearly software fee of $80 is applicable.
  • 🍻[Clear The Check Engine Light Yourself] Provides full system motorcycle obd2 diagnostic, component reset, and relearn functions for these motorcycles. Can retrieve and clear fault codes from the motorcycle's ECU, and analyze information from ABS, Engine, Transmission, Power Steering, and Meter systems.
  • 📢[Integrates over 30 relearn and adapt functions] MOTO 100 motorcycle code reader support for tire pressure monitoring system, idle adjustment self-adaptation reset, CO adjustment, A/F value reset, ABS control unit setting, reset calibration values, transmission memory reset, windshield adjustment, and gear sensor initialization.
Bestseller No. 5
KAWASAKI OBDII" rel="nofollow noopener sponsored" target="_blank"> LUTIFIX M3-A Motorcycle Diagnostic Motorcycle Code Reader Scanner Motorcycle Diagnostic Tool with Voltage Test Quick test for HONDA YAMAHA KAWASAKI OBDII
LUTIFIX M3-A Motorcycle Diagnostic Motorcycle Code Reader Scanner Motorcycle Diagnostic Tool with Voltage Test Quick test for HONDA YAMAHA KAWASAKI OBDII
  • 【Advanced M3 Motorcycle Diagnosis】LUTIFIX M3 Motorcycle Diagnostic is a handheld motorcycle diagnostic tool for mainstream motorcycle brands and can help technicians diagnose problems faster and make repairs. The Motorcycle Diagnostic Tool has functions such as voltage detection, multi-language selection, and unit switching. The Motorcycle Scanner has a clear interface and is easy to operate. M3 Motorcycle Diagnostic is a good helper for motorcycle maintenance.
  • 【M3-A Motorcycle System Diagnosis Features】M3 Motorcycle Diagnostic supports a wide range of functions. For example, supports scanning, identification and code reading of all systems of the current model, and reports the assembly status of all systems and whether there are fault codes for each system. Support to browse the assembly status and fault code description of all systems of the vehicle model. Support one-click code clearing of all systems. Display data stream with oscillogram.
  • 【M3-A Motorcycle Diagnostic Functions】The Motorcycle Code Reader Scanner support engine / ABS / Tire pressure / Anti-theft and other systems, this Motorcycle Code Reader Scanner can quickly read and clear diagnostic trouble codes, view freeze frame, display data stream and do active tests, get vehicle information.
  • 【Widely Application】The OBDII Motorcycle Fault Code Readers Scan Tools support the diagnosis of Asian, European and American multi-brand motorcycles. M3-A is suitable for HONDA,YAMAHA,KAWASAKI,OBDII.
  • 【Quick Tests & Multi-language】Quick test is to automatically scan the assembly status of all systems of the vehicle model and read the fault codes.Motorcycle OBD2 Scanner support Turkish,Spanish,Portuguese Vietnamese,Khmer,Thai,English,French,Chinese,Bahasa Indonesia,Traditional Chinese,multi-languages for your selection.
Bestseller No. 6
ANCEL MT500 PRO Motorcycle Diagnostic Tool, Motorcycle Scanner Fits for Harley Yamaha Honda Kawasaki Suzuki Indian Polaris BRP Victory Motorbike OBD2 Scanner, 30+ Reset, Android 5'' Touch Screen
  • 👍【Multifunctional Motorcycle Diagnostic Tool】MT500 PRO is an advanced motorcycle diagnostic tablet developed by ANCEL specifically for motorcycle enthusiasts. Bright 5" touchscreen & Android 5.1.1 OS & 8 Languages; Auto VIN & Scan; Online remote assistance and solve problems, One-click WIFI update; Full systems diagnosis for most popular motorcycle models; 30+ Resets like oil service reset, abs bleeding, etc.
  • ✅【Wider Motorcycle Coverage Than Others】 Compare with other similar motorcycle scan tool, MT500PRO added more popular motorcycle brands, it' not only compatible with Harley Yamaha Honda Indian Polaris BRP Victory diagnosis.Newly upgraded in 2023 with the addition of two more popular brands fit for Kawasaki Suzuki diagnosis. Plug and play, easy to use
  • ✅ [Manufacturer-level Diagnostic] MT500 PRO is a all-system motorcycle diagnostic tool. It can read and clear trouble codes and turn off the CEL when a check engine light comes on. Besides, it can also scan all the available electronic control modules of your motorcycle including Engine, ABS, TPMS, Suspensions, Ignition, EPS, Service system, Meter system, etc. to read/clear fault codes, and view live data.You can quickly and accurately find existing or potential problems, saving time and money
  • ✅ [Excluisive Advance Functions, Save Costs For You] MT500 PRO diagnostic tool with almost all daily maintenance services that necessary advanced functions for most motorcycle to meet the market trends and needs. Auto scan, auto VIN recognition, control module programming and coding, ECU setting, instrument coding, maintenance light reset, CO adjustment, idle speed adjustment, A/F value reset, ABS control unit setting etc. Help you solve all kinds of complex maintenance problems easily
  • ✅The ANCEL MT500PRO scanner diagnostic tool providing real-time data display for quick and accurate diagnostics. With its user-friendly touch screen interface, the Moto 100 OBD2 code reader allows for easy navigation and interpretation of the data streams. Whether you are a professional mechanic or a motorcycle enthusiast, this code reader is a valuable tool for troubleshooting and maintaining your motorcycle’s performance
Bestseller No. 7
ANCEL MT510 for Ducati Motorcycle OBD2 Scanner Diagnostic Tool with Full System Coverage - Oil Service Reset, TPS ECU Reset - Troubleshoot Fault Codes, Auto Vin - Full Color Display-1 Year Free Update
  • 👍Professional Diagnostic Tool for Ducati: The MT510 is a professional motorcycle diagnostic tool specifically designed for Ducati. It is compatible with the most popular makes, including Panigale, Monster, Multistrada, Scrambler, Diavel, and Hypermotard. The MT510 features a large full-color touchscreen with a user-friendly interface, making it easy to navigate through menus and access various functions.
  • 👍Oil Service & TPS Reset & ECU Reset: With the MT510 OBD scanners for motorcycles, you can maintain your motorcycle's optimal performance. It can reset the oil service reminder, calibrate the TPS sensor for better throttle response, and reset the ECU to resolve issues related to fuel mapping, ignition timing, and other performance parameters.
  • 👍Relearn Advanced Diagnostic Functions: Scan various systems, including the engine, ABS, instrument cluster, and more. It offers advanced diagnostic functions to read and clear fault codes, perform active tests, view freeze frame data, retrieve ECU information, and conduct component testing. It can also do VIN (chassis number) writing, Cylinder MAP vacuum adjustment, Enable/disable(ABS,RTS,Heated grips, Anti-theft), PIN code reset , Keys' reset, BAS Tuning, CO and Idle parameters reset and more.
  • 👍VIN Auto Detection: The MT510 can automatically detect and read the VIN (Vehicle Identification Number) of your connected Ducati motorcycle. This feature helps in locating the correct diagnostic socket and ensures accurate vehicle identification for efficient troubleshooting.
  • 👍Real-time Data Monitoring: The MT510 provides live data streaming, displaying real-time data from different sensors and modules in graphical or numerical form. This allows you to monitor the vehicle's performance parameters and identify any abnormalities or faults.
Bestseller No. 8
LINXINO Motorcycle Diagnostic Tool,Motorcycle OBD2 Scanner,OBD2 Clear fault codes,M3-C Motorcycle Scanner Compatible for SUZUKI,EUROV,VESPA and OBDII
  • 【Powerful Motorcycle Diagnostic Tool】LINXINO M3 Motorcycle Diagnostic is a handheld motorcycle diagnostic tool, This obd scanner diagnostic tool is used to diagnostic testing and repair of motorcycles. Universal Motorcycle Diagnostic tool has a voltage detection, a variety of languages to choose from, read and clear the fault code.etc. OBDII Motorcycle Fault Code Readers Scan Tools has a clear interface, easy to operate, and is a good helper for motorcycle repair.
  • 【System Diagnosis Features】The Code Readers Scan Tools support scanning, identification and code reading of all systems of the current model, and reports the assembly status of all systems and whether there are fault codes for each system. The code readers & scan tools support to browse the assembly status and fault code description of all systems of the vehicle model. Support one-click code clearing of all systems. Display data stream with oscillogram.
  • 【Multiple Support Functions】Motorcycle Diagnostic Tool support engine / ABS / Tire pressure / Anti-theft and other systems.Motorcycle Code Reader Scanner supports multiple functions,like Read system information,Read fault code,Clear fault code,Read data stream,Read freeze frame data, Actuator test and Service function (including idle speed regulation /throttle position learning, etc.)
  • 【Quick test & Voltage test】The motorcycle diagnostic tool support quick test and voltage test function. Quick test is to automatically scan the assembly status of all systems of the vehicle model and read the fault codes. The OBD battery voltage can be detected in real time.
  • 【Widely used & Multiple language】 M3-C Motorcycle diagnostic tool is suitable for SUZUKI,EUROV,VESPA and OBDII.Motorcycle System Diagnostic Test Measurement Tools provide multiple language selection for your convenience.
Bestseller No. 9
LUTIFIX M3-C Motorcycle Diagnostic Motorcycle Code Reader Scanner Motorcycle Diagnostic Tool with Voltage Test Quick test for SUZUKI EUROV VESPA OBDII
  • 【Advanced M3-C Motorcycle Diagnosis】LUTIFIX M3 Motorcycle Diagnostic is a handheld motorcycle diagnostic tool for mainstream motorcycle brands and can help technicians diagnose problems faster and make repairs. The Motorcycle Diagnostic Tool has functions such as voltage detection, multi-language selection, and unit switching. The Motorcycle Scanner has a clear interface and is easy to operate. M3 Motorcycle Diagnostic is a good helper for motorcycle maintenance.
  • 【M3-C Motorcycle System Diagnosis Features】M3 Motorcycle Diagnostic supports a wide range of functions. For example, supports scanning, identification and code reading of all systems of the current model, and reports the assembly status of all systems and whether there are fault codes for each system. Support to browse the assembly status and fault code description of all systems of the vehicle model. Support one-click code clearing of all systems. Display data stream with oscillogram.
  • 【M3-C Motorcycle Diagnostic Functions】The Motorcycle Code Reader Scanner support engine / ABS / Tire pressure / Anti-theft and other systems, this Motorcycle Code Reader Scanner can quickly read and clear diagnostic trouble codes, view freeze frame, display data stream and do active tests, get vehicle information.
  • 【Widely Application】The OBDII Motorcycle Fault Code Readers Scan Tools support the diagnosis of Asian, European and American multi-brand motorcycles. M3-C is suitable for SUZUKI ,EUROV,VESPA and OBDII.
  • 【Quick Tests & Multi-language】Quick test is to automatically scan the assembly status of all systems of the vehicle model and read the fault codes.Motorcycle OBD2 Scanner support Turkish,Spanish,Portuguese Vietnamese,Khmer,Thai,English,French,Chinese,Bahasa Indonesia,Traditional Chinese,multi-languages for your selection.
Bestseller No. 10
NEXAS NexLink OBD2 Scanner Bluetooth 5.0,Wireless Compatible with Third-Party Apps,Car & Motorcycle Universal Code Reader,Check Engine Fault OBDII Adapter Scan Tool for ios, Android & Windows
  • 🔥[Universal OBD2 Scanner Bluetooth 5.0] Tired of paying hundreds of dollars for the shop just to find out what’s wrong your car when engine light turns on? Nexlink obd2 scanner bluetooth come to help, it can not only read the engine fault code quickly, explain you what the code means, but also clear the code easily. More importantly, our obd2 code reader is equipped with more advanced functions: live data stream, battery health check, I/M Readiness, diagnostic report and more.
  • 🏅[Works on iOS, Android, Windows] Functions verified by Nexlink users: testing hybrid battery, monitoring performance parameters, diagnostic ignition coil problems, providing an operational display of engine values including mileage estimates, emissions ready or not readout, real-time gas mileage readings & etc. Used in conjunction with the right third-party app, it can perform all the functions of a stand-alone obd2 scanner and more.
  • 🏅[Wide Third Party Apps to Choice] Nexlink bluetooth adapter to make it easier to achieve functions over OBDII. Works with Dr. Prius, Torque Lite/Pro, Garage Pro, LeafSpy, BimmerCode/BimmerLink,, CarScanner, TuneECU, DashCommand, Motoscan, Autoscanner ELM OBD2, Harrys LapTimer, FORScan, OBD Auto Doctor, HybridAssistant, and more. Download them via Google Play or the App Store (Bluetooth LE for iOS, Bluetooth for Android & Windows).
  • 🥉[2 IN1 Car & Motorcycle Scan Tool] Nexlink obdii scanner bluetooth allows you to perform engine code, ID, and live data reading, fault code clearing, actuator testing, acceleration testing, engine service intervaling, coding and more on motorcycle. For BMW motorcycles(C, F, G, K, R, S and Husqvarna series) pls chose Motoscan and TuneECU APP, and for Triumph, Aprilia,Benelli, Ducati & MotoGuzzi,Morini, Gilera, Husqvarna, KTM,CCM,pls chose TuneECU only.
  • 🥇[Drive with Confidence] With dashboard function, you can monitor your car’s status in real-time on phone, including coolant temperature, average speed, engine RPM, distance travelled, inst fuel rate, fuel used, turn your phone into a vehicle dashboard with our obd reader. Also you can set up a threshold for coolant temperature,speed etc, there will be color or sound alarm when the threshold is exceeded, to ensure safe driving.

Last update on 2024-07-11 / Affiliate links / Images from Amazon Product Advertising API

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