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July 30, 2021 NHTSA CAMPAIGN NUMBER: 21V593000
Loss of Oil Pressure May Cause Engine Stall
An engine stall can increase the risk of a crash.
NHTSA Campaign Number: 21V593
Manufacturer Kawasaki Motors Corp., U.S.A.
Components ENGINE AND ENGINE COOLING
Potential Number of Units Affected 1,523
Summary
Kawasaki Motors Corp., U.S.A. (KMC) is recalling certain 2020-2021 Ninja H2, Ninja H2 Carbon, Z H2, 2021 Ninja H2 SX SE+, ZX-10R, ZX-10R ABS, ZX-10R KRT Edition, ZX-10R ABS KRT Edition, ZX-10RR, and Z H2 SE motorcycles. The engine oil pressure relief valve may come apart, causing a loss of oil pressure and possible engine stall.
Remedy
Dealers will replace the relief valve, free of charge. Owner notification letters were mailed August 23, 2021. Owners may contact KMC customer service at 1-866-802-9381. KMC’s number for this recall is MC21-05.
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.
Subject
On affected units, the components of the relief valve that maintain the oil pressure of the engine may come apart due to improper assembly. When the oil pressure warning indicator is turned on, the engine becomes poorly lubricated. This could result in an engine stall, increasing the risk of a crash.
Kawasaki Action
Initiate Campaign:
Kawasaki has initiated a Recall campaign to repair all eligible units. The repair consists of replacing the oil pressure relief valve.
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 30 of this bulletin.
Repair Procedure – ZR1000K/L
ZR1000K/L Models Only
Refer to service manual 99832-0067-04 for detailed information related to parts removal and installation.
Middle Fairing Removal, Left & Right Side
Refer to Chapter 15, Frame / Fairings /Middle Fairing Removal
Lower Fairing Removal
Refer to Chapter 15, Frame / Fairings / Lower Fairing Removal
Muffler Body Removal
Refer to Chapter 5, Engine Top End / Muffler/Muffler Body Removal
Take the oxygen sensor lead connector [A] off the bracket [B], and disconnect it.
NOTE:
Do not remove the oxygen sensor from the exhaust pipe.
Remove and retain coolant reserve tank bolts [A].
Secure the coolant reserve tank to the frame with a strap or a zip tie so the weight of the tank is not supported by the overflow hose.
Remove and retain the water pipe bolt [A] from the right side of the vehicle.
Remove and discard the upper radiator bolts [A] from both sides of the vehicle.
Remove and retain the exhaust pipe bolt [A] and washer [B] from the left side of the vehicle.
Remove and retain the lower radiator bolt [A] from the left side of the vehicle.
Remove and retain the exhaust pipe holder nuts [A].
Shift the radiator forward and remove the exhaust pipe [B].
Remove and discard the copper exhaust pipe gaskets [not shown in this photo].
NOTE:
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Remove and retain the engine oil drain bolt to drain the engine oil.
Discard the drain bolt gasket.
Remove and retain oil pan bolts [A].
Remove and retain bracket [B].
Remove and retain clamp [C].
Remove and retain oil pan [D].
Remove and discard oil pan gasket [E].
Remove and retain the oil screen [A].
Discard the o-ring [not shown].
Remove the oil pressure relief valve [A].
Remove and retain the oil pressure relief valve cover [B].
Inspect the oil pressure relief valve for missing parts.
- A: If the oil pressure relief valve has come apart, locate and remove the relief valve components from inside the engine and inspect the engine for damage caused by relief valve components and repair as required. Proceed to the next step.
- B: If the oil pressure relief valve is fully assembled, proceed to the next step.
Install the oil pressure relief valve cover [B].
IMPORTANT NOTE:
Do not apply too much non-permanent locking agent to the threads as this may block the oil passage.
Apply a non-permanent locking agent to the threads of the new oil pressure relief valve [A] [ref 1].
Install the oil pressure relief valve [A] and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Grease the new o-ring [ref 8] from the repair kit.
Install the oil screen [A] using the new o-ring [ref 8].
Install the oil pan [C] using the new oil pan gasket [E][ref 2][install dry] from the repair kit using 3 or 4 bolts hand tightened.
Install clamp [B].
Install bracket [A]
Install the remaining oil pan bolts and tighten them in the sequence 1~18 as shown to 89 in·lb (1.0 kgf·m, 10 N·m).
Lightly grease the new exhaust pipe gaskets [ref 5] from the repair kit and install them.
Install the exhaust pipe [B] and tighten the exhaust pipe holder nuts [A] gradually in the sequence shown to 15 ft·lb (2.0 kgf·m, 20 N·m).
NOTE:
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Install the exhaust pipe washer [B] and bolt [A] and and tighten to 25 ft·lb (3.5 kgf·m, 34 N·m).
Install new upper radiator bolts [ref 7] from the repair kit on both sides of the vehicle and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Install the lower radiator bolt [A] and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
Install the water pipe bolt [A] and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
Install the coolant reserve tank bolts [A] and tighten to 4.4 in·lb (0.05 kgf·m, 0.5 N·m).
Remove the strap or zip tie used to secure the tank during disassembly.
Install the oxygen sensor lead connector [B] on bracket [A].
Refer to service manual 99832-0067-04 for detailed information related to parts removal and installation.
Muffler Body Installation
Refer to Chapter 5, Engine Top End / Muffler/Muffler Body Installation Install a new muffler joint gasket [ref 6] from the repair kit.
Lower Fairing Installation
Refer to Chapter 15, Frame / Fairings / Lower Fairing Installation
Middle Fairing Installation, Left & Right Side
Refer to Chapter 15, Frame / Fairings /Middle Fairing Installation
Refer to Chapter 2, Periodic Maintenance Procedures / Engine Lubrication System / Engine Oil Change
Install a new drain bolt gasket [ref 3] and engine oil filler plug o-ring [ref 9] from the repair kit
ZX1002L/M/N Models Only
Refer to service manual 99832-0194-02 for detailed information related to parts removal and installation.
Fuel Tank Removal
Refer to Chapter 3, Fuel System (DFI) / Fuel Tank / Fuel Tank Remove
Lower Fairing Removal
Refer to Chapter 15, Frame / Fairings / Lower Fairing Removal
Oil Cooler Removal
Refer to Chapter 7, Engine Lubrication System / Oil Cooler / Oil Cooler Removal
Premuffler Chamber Removal
Refer to Chapter 5, Engine Top End / Muffler / Premuffler Chamber Removal
Disconnect the oxygen sensor lead connector [A].
NOTE:
Do not remove the oxygen sensor from the exhaust pipe.
Open clamps [A].
Remove bolt [A] and lower oil cooler bracket [B]
Remove the exhaust pipe holder nuts [A].
Remove the exhaust pipe [B].
Remove and discard the copper exhaust pipe gaskets [not shown]
NOTE:
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Remove and discard the oil filter.
Remove and retain the oil pan bolts [A].
Remove and retain the clamps [B].
Remove and retain the oil pan [C].
Remove and discard the oil pan gasket [not shown].
Remove the oil pressure relief valve [A].
Inspect the oil pressure relief valve for missing parts.
- A: If the oil pressure relief valve has come apart, locate and remove the relief valve components from inside the engine and inspect the engine for damage caused by relief valve components and repair as required. Proceed to the next step.
- B: If the oil pressure relief valve is fully assembled, proceed to the next step.
IMPORTANT NOTE:
Do not apply too much non-permanent locking agent to the threads as this may block the oil passage.
Apply non-permanent locking agent to the threads of the new oil pressure relief valve [A] [ref 1].
Install the oil pressure relief valve [A] and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Apply grease to new o-rings [A] [ref 10] and [B] [ref 5] and install them. Face the chamfered side [C] downward.
Install the oil screen [D].
Fit the claws [E] on each side of the crankcase rib [F].
Apply grease to new o-ring [G] [ref 4] and install on the oil pipe [P].
Install the a new oil pan gasket [A] [ref 3] from the repair kit.
Install the oil pan [D], clamps [B] and bolts [C].
Tighten the oil pan bolts [C] in the sequence (1~18) shown to 89 in·lb (1.0 kgf·m, 10 N·m).
Install new exhaust pipe gaskets [ref 7] from the repair kit.
Install the exhaust pipe [B] and holder nuts [A] then tighten them in incrementally as shown in the diagram below to a final torque of 15 ft·lb (2.0 kgf·m, 20 N·m).
NOTE:
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Install the lower oil cooler bracket [B] using a new bolt [A] [ref 16] from the repair kit and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
Secure the oxygen sensor lead [B] with clamps [A].
Connect the oxygen sensor lead connector [A].
ZX1002L/M/N Models Only
Refer to service manual 99832-0194-02 for detailed information related to parts removal and installation.
Premuffler Chamber Installation
Refer to Chapter 5, Engine Top End / Muffler / Premuffler Chamber Installation Install new gaskets [ref 7, 8 & 9].
Oil Cooler Installation
Refer to Chapter 7, Engine Lubrication System / Oil Cooler / Oil Cooler Installation Install new bolts [ref 12, 13, 14 & 15] and o-rings [ref 14].
Refer to Chapter 2, Periodic Maintenance Procedures / Engine Lubrication System / Engine Oil Change Install new drain bolt gasket [ref 2], oil filter [ref 6] and fill plug o-ring [ref 11].
Lower Fairing Installation
Refer to Chapter 15, Frame / Fairings / Lower Fairing Installation
Fuel Tank Installation
Refer to Chapter 3, Fuel System (DFI) / Fuel Tank / Fuel Tank Install
Repair Procedure – ZX1002D
ZX1002D Models Only
Refer to service manual 99832-0012-02 for detailed information related to parts removal and installation.
Lower Fairing Removal
Refer to Chapter 15, Frame / Fairings / Lower Fairing Removal
Fuel Tank Removal
Refer to Chapter 3, Fuel System (DFI) / Fuel Tank / Fuel Tank Removal
Muffler Body Removal
Refer to Chapter 5, Engine Top End / Muffler / Muffler Body Installation
Remove and retain the water pipe bolt [A] from the right side of the vehicle.
Remove and retain the lower radiator mounting bolt [A] from the left side of the vehicle.
Remove and retain the upper radiator mounting bolt [A] from both sides of the vehicle.
Disconnect the oxygen sensor connector [A].
NOTE:
Do not remove the oxygen sensor from the exhaust pipe.
Free the oxygen sensor lead [B] from the clamps [A].
Remove the clamps [A] to free the oxygen sensor lead [B].
Refer to service manual 99832-0012-03 for detailed information related to parts removal and installation.
Exhaust Butterfly Valve Cable Removal
Refer to Chapter 5, Engine Top End / Muffler / Exhaust Butterfly Valve Cable Removal
Remove and retain the exhaust pipe mounting bolt [A] and washer [B].
Remove and retain the exhaust pipe holder nuts [A].
Shift the radiator forward and remove the exhaust pipe.
Remove and discard the copper exhaust pipe gaskets
NOTE:
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Remove and retain the engine oil drain bolt to drain the engine oil.
Discard the drain bolt gasket.
Remove and retain the oil pan bolts [A].
Remove and retain bracket [B].
Remove and retain the oil pan [C].
Remove and discard the oil pan gasket.
Remove the oil pressure relief valve [A].
Remove and retain the oil screen [A].
Inspect the oil pressure relief valve for missing parts.
- A: If the oil pressure relief valve has come apart, locate and remove the relief valve components from inside the engine and inspect the engine for damage caused by relief valve components and repair as required. Proceed to the next step.
- B: If the oil pressure relief valve is fully assembled, proceed to the next step.
IMPORTANT NOTE:
Do not apply too much non-permanent locking agent to the threads as this may block the oil passage.
Apply non-permanent locking agent to the threads of the new oil pressure relief valve [A] [ref 1].
Install the oil pressure relief valve [A] and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Apply grease to the new o-ring [A] [ref 7] from the repair kit and install it.
Run the breather hose [B] in to the hole [C].
Install the oil screen so that the crankcase rib [D] fits to the notch [E] of the oil screen [F].
Install the new oil pan gasket [C] [ref 2] from the repair kit.
Install the oil pan [A], bracket [B] and bolts.
Tighten the oil pan bolts to 89 in·lb (1.0 kgf·m, 10 N·m). in the sequence shown.
NOTE:
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Lightly grease and install the new exhaust pipe gaskets [ref 5] from the repair kit.
Install the exhaust pipe [B] and exhaust pipe holder nuts [A] in the sequence shown below to 15 ft·lb (2.0 kgf·m, 20 N·m).
Install the exhaust pipe mounting washer [B] and bolt [A] and tighten to 25 ft·lb (3.5 kgf·m, 34 N·m).
Secure the oxygen sensor lead [B] with clamps [A].
Secure the oxygen sensor lead [B] with clamps [A].
Connect the oxygen sensor connector [A].
Install the upper radiator mounting bolt [A] on both sides of the vehicle and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Install the lower radiator mounting bolt [A] on the left side of the vehicle and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Install the water pipe bolt [A] on the right side of the vehicle and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
ZX1002D Models Only
Refer to service manual 99832-0012-02 for detailed information related to parts removal and installation.
Muffler Body Installation
Refer to Chapter 5, Engine Top End / Muffler / Muffler Body Installation
Install a new muffler joint gasket [ref 6] from the repair kit.
Fuel Tank Installation
Refer to Chapter 3, Fuel System (DFI) / Fuel Tank / Fuel Tank Installation
Refer to Chapter 2, Periodic Maintenance Procedures / Engine Lubrication System / Engine Oil Change
Install a new engine oil drain gasket [ref 3] and oil filler plug o-ring [ref 8] from the repair kit.
Lower Fairing Installation
Refer to Chapter 15, Frame / Fairings / Lower Fairing Installation
Repair Procedure – ZX1002J
ZX1002J Models Only
Refer to service manual 99832-0150-02 (ZX1002J) for detailed information related to parts removal and installation.
Middle Fairing Removal Right and Left Side
Refer to Chapter 15, Frame / Fairings / Middle Fairing Removal
Lower Fairing Removal Right and Left Side
Refer to Chapter 15, Frame / Fairings / Lower Fairing Removal
Fuel Tank Removal
Refer to Chapter 3, Fuel System (DFI) / Fuel tank / Fuel Tank Removal
Rear Intake Duct Removal
Refer to Chapter 15, Frame / Fairings / Intake Duct Removal
Muffler Body Removal
Refer to Chapter 5, Engine Top End / Muffler / Muffler Body Removal
Disconnect the oxygen sensor connector [A].
NOTE:
Do not remove the oxygen sensor from the exhaust pipe.
Free the oxygen sensor lead from clamp [A].
Free the oxygen sensor lead [A] from the bracket [B].
Remove the water pipe bolt [A] from the right side of the vehicle.
Remove the lower radiator mounting bolt [A].
Remove the lower radiator mounting bracket bolt [A] and lower radiator mounting bracket [B].
Remove the ABS hydraulic unit bracket bolts [A].
While lifting the ABS hydraulic unit [A], remove the upper radiator mounting bolt [B] (both sides).
Exhaust Butterfly Valve Cable Removal
Refer to Chapter 5, Engine Top End / Muffler / Exhaust Butterfly Valve Cable Removal
Remove the Exhaust Pipe Mounting Bolt [A] and Washer [B].
Remove and retain the exhaust pipe holder nuts [A].
Shift the radiator forward and remove the exhaust pipe.
Remove and discard the copper exhaust pipe gaskets.
NOTE:
Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
Remove and retain the engine oil drain bolt to drain the engine oil.
Discard the drain bolt gasket.
Remove and retain the oil pan bolts [A].
Remove and retain bracket [B].
Remove and retain the oil pan [C].
Remove and discard the oil pan gasket [D].
Remove and retain the oil screen [A].
Remove and discard the oil screen o-ring [not shown].
Remove the oil screen [B].
Remove the oil pressure relief valve [A].
Inspect the oil pressure relief valve for missing parts.
- A: If the oil pressure relief valve has come apart, locate and remove the relief valve components from inside the engine and inspect the engine for damage caused by relief valve components and repair as required. Proceed to the next step.
- B: If the oil pressure relief valve is fully assembled, proceed to the next step.
IMPORTANT NOTE:
Do not apply too much non-permanent locking agent to the threads as this may block the oil passage.
Apply non-permanent locking agent to the threads of the new oil pressure relief valve [A] [Ref 1].
Install the oil pressure relief valve [A] and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Install the the oil screen [B].
Grease the new o-ring [ref 8] from the repair kit.
Install the oil screen [A] using the new o-ring [ref 8].
Install the oil pan [C] using the new gasket [B] [ref 2] from the repair kit using 3 or 4 bolts hand tightened.
Install bracket [A]
Install the remaining oil pan bolts [A] and tighten them in the sequence shown 1~18 as shown to 89 in·lb (1.0 kgf·m, 10 N·m).
Lightly grease and install the new exhaust pipe gaskets [ref 6] from the repair kit.
Install the exhaust pipe [B] and exhaust pipe holder nuts [A] in the sequence shown below to 15 ft·lb (2.0 kgf·m, 20 N·m).
Install the exhaust pipe washer [B] and mounting bolt [A] and tighten to 25 ft·lb (3.5 kgf·m, 34 N·m).
Install the upper radiator mounting bolt [A] on both sides of the vehicle and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Install the ABS hydraulic unit bracket bolts and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
Install the lower radiator mounting bracket [B] and bolt [A] and tighten to 11 ft·lb (1.5 kgf·m, 15 N·m).
Install the lower radiator mounting bolt [A] and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
Install the water pipe bolt [A] and tighten to 89 in·lb (1.0 kgf·m, 10 N·m).
Secure the oxygen sensor lead [A] with bracket [B].
Secure the oxygen sensor lead with clamp [A].
Connect the oxygen sensor connector [A].
ZX1002J Models Only
Refer to service manual 99832-0150-02 (ZX1002J) for detailed information related to parts removal and installation.
Muffler Body Installation
Refer to Chapter 5, Engine Top End / Muffler / Muffler Body Installation
Install a new muffler joint gasket [ref 5] from the repair kit.
Exhaust Butterfly Valve Cable Installation
Refer to Chapter 5, Engine Top End / Muffler / Exhaust Butterfly Valve Cable Installation
Install a new butterfly valve nut [ref 7] and foot peg bracket bolts [ref 9] from the repair kit.
Rear Intake Duct Installation
Refer to Chapter 15, Frame / Fairings / Intake Duct Installation
Fuel Tank Installation
Refer to Chapter 3, Fuel System (DFI) / Fuel tank / Fuel Tank Installation
Lower Fairing Installation Right and Left Side
Refer to Chapter 15, Frame / Fairings / Lower Fairing Installation
Install new o-rings [ref 10] from the repair kit.
Middle Fairing Installation Right and Left Side
Refer to Chapter 15, Frame / Fairings / Middle Fairing Installation
Refer to Chapter 2, Periodic Maintenance Procedures / Engine Lubrication System / Engine Oil Change
Install a new enging oil drain bolt gasket [ref 3] and engine oil filler plug o-ring [ref 11] from the repair kit.
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 2020 Z H2, NINJA H2, NINJA H2 CARBON and NINJA H2R and 2021 Z H2, Z H2 SE, NINJA H2 SX SE+, NINJA H2, NINJA H2 CARBON, NINJA ZX-10R, NINJA ZX-10R KRT EDITION, NINJA ZX-10R RR models.
The reason for this notice:
On affected units, the components of the relief valve that adjusts the oil pressure of the engine may come apart due to improper assembly. When the oil pressure warning indicator is turned on, the engine becomes poorly lubricated. This could result in an engine stall, increasing the risk of a crash. Our records indicate that you have purchased one of these units.
What Kawasaki and your dealer will do:
Kawasaki has authorized your dealer to replace the oil pressure relief valve on your motorcycle free of charge. The actual repair will take up to three hours depending on the model and 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 are unable to transport your motorcycle to your nearest Kawasaki dealer, please contact Kawasaki Motors Corp., U.S.A.
to make arrangements for the transportation and repair of your motorcycle. The transportation and repair will be conducted with no cost to you.
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) 802-9381 (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: 1-800-424-9153); 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 => KAWASAKI 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. Continued on next page
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.
SEOCONTENT-START
SERVICE MC 21-05 August 19, 2021 Page 1 of 30 Eligibility Eligible Units Year Model Model Codes 2020 Z H2 ZR1000KLF ZR1000KLFL 2020 NINJA H2 NINJA H2 CARBON ZX1002JLFL ZX1002JLFAL 2021 Z H2 ZR1000KMFNL 2021 Z H2 SE ZR1000LMFNL 2021 NINJA H2 SX SE+ ZX1002DMFNL 2021 NINJA H2 NINJA H2 CARBON ZX1002JMFNL ZX1002JMANL 2021 NINJA ZX-10R ABS NINJA ZX-10R ABS KRT EDITION ZX1002LMFNL ZX1002LMFAL 2021 NINJA ZX-10R NINJA ZX-10R KRT EDITION ZX1002MMFNL ZX1002MMFAL 2021 NINJA ZX-10RR ZX1002NMFNL 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. 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: o 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. THIS BULLETIN IS OF THE HIGHEST PRIORITY AND MUST BE ACTED UPON IMMEDIATELY TO ENSURE CUSTOMER SAFETY. RECALL TITLE: 2020~2021 NINJA H2™, Z H2 & NINJA® ZX™-10R OIL PRESSURE RELIEF VALVE REPLACEMENT Page 2 Parts Information 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: o 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. Repair Kit Part Number: Install repair parts on all eligible vehicles. Order parts to complete this campaign through K-Dealer as outlined in Service Bulletin SP15-03. KIT, RELIEF VALVE MC21-05 P/N 99999-0816, ZR1000K/L Ref Contents Qty 1 VALVE-ASSY-RELIEF 1 2 GASKET, OIL PAN 1 3 GASKET, 12X22X2 (Engine Oil Drain) 1 4 GASKET (Coolant Drain) (NOT USED) 1 5 GASKET, EXHAUST PIPE 4 6 GASKET, MUFFLER JOINT 1 7 BOLT, FLANGED (Upper Radiator) 2 8 RING-O (Oil Screen) 1 9 RING-O (Engine Oil Filler Plug) 1 KIT, RELIEF VALVE MC21-05 P/N 99999-0815, ZX1002L/M/N Ref Contents Qty 1 VALVE-ASSY-RELIEF 1 2 GASKET, 12X22X2 (Engine Oil Drain) 1 3 GASKET, OIL PAN 1 4 O RING, 18MM (Oil Pipe) 1 5 RING-O (Crankcase Fitting) 1 6 FILTER-ASSY-OIL 1 7 GASKET, EXHAUST PIPE 4 8 GASKET, 76X84X30 (Exhaust Pipe) 1 9 GASKET, 50.8X62X30 (Muffler) 1 10 RING-O (Oil Screen) 1 11 RING-O (Engine Oil Filler Plug) 1 12 BOLT (Upper Oil Cooler) 3 13 BOLT (Oil Cooler Hose Fitting) 2 14 O RING (Oil Cooler) 2 15 BOLT (Oil Cooler) 1 16 BOLT, SOCKET, 8X18 (Oil Cooler Bracket) Parts Information (continued) KIT, RELIEF VALVE MC21-05 P/N 99999-0817, ZX1002D Ref Contents Qty 1 VALVE-ASSY-RELIEF 1 2 GASKET, OIL PAN 1 3 GASKET, 12X22X2 (Engine Oil Drain) 1 4 GASKET (Coolant Drain) (NOT USED) 1 5 GASKET, EXHAUST PIPE 4 6 GASKET, MUFFLER JOINT 1 7 RING-O (Oil Screen) 1 8 RING-O (Engine Oil Filler Plug) 1 KIT, RELIEF VALVE MC21-05 P/N 99999-0818, ZX1002J Ref Contents Qty 1 VALVE-ASSY-RELIEF 1 2 GASKET, OIL PAN 1 3 GASKET, 12X22X2 (Engine Oil Drain) 1 4 GASKET (Coolant Drain) (NOT USED) 1 5 GASKET, MUFFLER JOINT 1 6 GASKET, EXHAUST PIPE 4 7 NUT, LOCK, FLANGED, 10MM (Butterfly Valve) 1 8 RING-O (Oil Screen) 1 9 BOLT (Foot Peg Bracket) 2 10 O RING (Lower Cowling) 2 11 RING-O (Engine Oil Filler Plug) Workflow Overview INSPECT OIL PRESSURE RELIEF VALVE REPLACE OIL PRESSURE RELIEF VALVE INSPECT ENGINE FOR DAMAGE CAUSED BY RELIEF VALVE COMPONENTS AND REPAIR AS REQUIRED LOCATE AND REMOVE THE RELIEF VALVE COMPONENTS FROM INSIDE THE ENGINE VALVE WITHOUT MISSING PIECES VALVE WITH MISSING PIECES REPLACE OIL PRESSURE RELIEF VALVE REMOVE OIL PRESSURE RELIEF VALVE REPAIR PROCEDURE TABLE OF CONTENTS MODEL PAGE ZR1000K/L 5~10 ZX1002L/M/N 11~14 ZX1002D 15~20 ZX1002J 21~28 Proceed to the Warranty section on page 29 of this bulletin. Warranty Information Repair Verification 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. See the Warranty Policies and Procedures Manual (claim type 3 information) for detailed instructions when submitting the Warranty Claim. ZR1000K/L ZX1002L/M/N ZX1002D ZX1002J Job Code 22558 22559 22560 22561 Flat Rate Time 1.4 hr 1.9 hr 2.7 hr 2.7 hr Claim Type 3 3 3 3 Part Number 99999-0816 99999-0815 99999-0817 99999-0818 Description KIT, Oil Pressure Relief Valve, MC21-05 KIT, Oil Pressure Relief Valve, MC21-05 KIT, Oil Pressure Relief Valve, MC21-05 KIT, Oil Pressure Relief Valve, MC21-05 Quantity 1 1 1 1 • Make a yellow paint mark [A] at the beginning of the VIN on the right hand side of the steering head to serve as repair verification. NOTE: o 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. A CALL KAWASAKI DEALER CARE AT (800) 854-3800 FOR AUTHORIZATION TO REPAIR ENGINE DAMAGE CAUSED BY AN OIL PRESSURE RELIEF VALVE THAT HAS COME APART. YELLOW PAINT MARK Page 30 2020~2021 NINJA H2TM & NINJA® ZXTM-10R OIL PRESSURE RELIEF VALVE REPLACEMENT IMPORTANT SAFETY RECALL NHTSA RECALL NO. 21V-593 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 2020 Z H2, NINJA H2, NINJA H2 CARBON and NINJA H2R and 2021 Z H2, Z H2 SE, NINJA H2 SX SE+, NINJA H2, NINJA H2 CARBON, NINJA ZX-10R, NINJA ZX-10R KRT EDITION, NINJA ZX-10RR models. The reason for this notice: On affected units, the components of the relief valve that maintain the oil pressure of the engine may come apart due to improper assembly. When the oil pressure warning indicator is turned on, the engine becomes poorly lubricated. This could result in an engine stall, increasing the risk of a crash. Our records indicate that you have purchased one of these units. What Kawasaki and your dealer will do: Kawasaki has authorized your dealer to replace the oil pressure relief valve on your motorcycle free of charge. The actual repair will take up to three hours depending on the model and 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 are unable to transport your motorcycle to your nearest Kawasaki dealer, please contact Kawasaki Motors Corp., U.S.A. to make arrangements for the transportation and repair of your motorcycle. The transportation and repair will be conducted with no cost to you. 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) 802-9381 (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: 1-800-424-9153); 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 => KAWASAKI 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.**************************************************************************************************************Continued on next page
Kawasaki Motors Corp., U.S.A.
P.O. Box 25252, Santa Ana, California 92799-5252
2020~2021 NINJA H2TM & NINJA® ZXTM-10R OIL PRESSURE RELIEF VALVE REPLACEMENT
IMPORTANT SAFETY RECALL
NHTSA Recall No. 21V-593
THIS NOTICE APPLIES TO YOUR VEHICLE VIN: 00000000000000000
CUSTOMER NAME ZX1002XXX: MC21-05
STREEN NAMEE FRAME:
CITY, STATE, ZIP DATE: 0000000 AUGUST, 23 2021
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 2020 Z H2, NINJA H2, NINJA H2 CARBON and NINJA H2R and 2021 Z H2, Z H2 SE, NINJA H2 SX SE+, NINJA H2, NINJA H2 CARBON, NINJA ZX-10R, NINJA ZX-10R KRT EDITION, NINJA ZX-10R RR models.
The reason for this notice: On affected units, the components of the relief valve that adjusts the oil pressure of the engine may come apart due to improper assembly. When the oil pressure warning indicator is turned on, the engine becomes poorly lubricated. This could result in an engine stall, increasing the risk of a crash. Our records indicate that you have purchased one of these units.
What Kawasaki and your dealer will do: Kawasaki has authorized your dealer to replace the oil pressure relief valve on your motorcycle free of charge. The actual repair will take up to three hours depending on the model and 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 are unable to transport your motorcycle to your nearest Kawasaki dealer, please contact Kawasaki Motors Corp., U.S.A. to make arrangements for the transportation and repair of your motorcycle. The transportation and repair will be conducted with no cost to you.
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)802-9381 (toll-free) between 7:00 a.m. and 4:00 p.m. PT Monday through Friday. Please have your VehicleIdentification 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: 1-800-424-9153); 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 => KAWASAKI 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.
Continued on next page
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.
SEOCONTENT-END
9 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| KAWASAKI | ZR1000K | 2020-2021 |
| KAWASAKI | ZR1000L | 2021 |
| KAWASAKI | ZX1002D | 2021 |
| KAWASAKI | ZX1002J | 2020-2021 |
| KAWASAKI | ZX1002L | 2021 |
| KAWASAKI | ZX1002M | 2021 |
| KAWASAKI | ZX1002N | 2021 |
11 Associated Documents
Recall 573 Report – Amendment 2
RCLRPT-21V593-9785.PDF 219.319KB
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Defect Notice 573 Report
RCLRPT-21V593-9528.PDF 219.318KB
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Recall Acknowledgement
RCAK-21V593-4492.pdf 788.241KB
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Recall 573 Report – Amendment 1
RCLRPT-21V593-4025.PDF 219.319KB
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Recall Quarterly Report #2, 2021-4
RCLQRT-21V593-0367.PDF 211.252KB
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Remedy Instructions and TSB
RCRIT-21V593-7539.pdf 10039.459KB
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ISSUED Owner Notification Letter(Part 577)
RCONL-21V593-8597.pdf 146.569KB
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Recall 573 Report – AMENDMENT 3
RCLRPT-21V593-1502.PDF 219.319KB
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Recall 573 Report – Amendment 5
RCLRPT-21V593-1068.PDF 219.716KB
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Recall 573 Report – Amendment 4
RCLRPT-21V593-8569.PDF 219.312KB
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Recall Quarterly Report #3, 2022-1
RCLQRT-21V593-0960.PDF 211.337KB
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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=21V593&docType=RCL
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