MC 20-08

SERVICE

September 11, 2020
Page 1 of 7

TITLE: NINJA® ZX™-6R, ABS & KRT EDITION HORN HARNESS REPLACEMENT

FACTORY DIRECTED MODIFICATION
IMMEDIATE REPAIR REQUIRED
Eligibility

Kawasaki Action

Eligible Units
Year

Model Name

Model Codes

2019

NINJA ZX-6R ABS
NINJA ZX-6R ABS KRT EDITION
NINJA ZX-6R ABS KRT EDITION
NINJA ZX-6R ABS
NINJA ZX-6R
NINJA ZX-6R

ZX636GKF
ZX636GKFA
ZX636GKFAL
ZX636GKFL
ZX636HKF
ZX636HKFL

2020

NINJA ZX-6R ABS
NINJA ZX-6R ABS KRT EDITION
NINJA ZX-6R ABS
NINJA ZX-6R
NINJA ZX-6R

ZX636GLF
ZX636GLFAL
ZX636GLFL
ZX636HLF
ZX636HLFL

Verify individual vehicle 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 eligible units, the horn harness can break due
to engine vibration resulting in an inoperative horn.

Initiate Campaign:
Kawasaki has initiated an FDM campaign to repair
all eligible units. The repair consists of replacing the
horn harness.
Notify Registered Owners:
Kawasaki is sending an FDM letter to all registered
owners of eligible units. A copy of the letter is printed
on page 7 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.
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 FDM 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.

©2020, Kawasaki Motors Corp., U.S.A.

Parts Information
Repair Kit Part Number:
Install the repair parts on all eligible units.

Kit, Horn Harness, MC20-08
P/N 99999-0771

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

A
1

Ref

Contents

Qty

1

Harness

1

2

Tape (Protective Sheet)

2

3

Band

3

4

Tape (Roll)

1

A
2

A
3

A
4

Repair Procedure
Refer to the appropriate sections of Service Manual 99832-0014-02 for information and procedures related
to parts removal and installation.

•

Remove the front seat.

•

Disconnect the negative battery terminal.

•

Remove the left upper inner fairing (rear) [F].

F

•

Disconnect both horn connectors [C]

•

Remove horn harness from guide [G].
C

C

Page 2

G

Repair Procedure (Continued)
•

Carefully bring the horn harness connectors
up from under the handlebar through the
opening where the fairing was removed.

•

Line up both harnesses as shown.

•

Cut both harnesses to the same length using
the base of the boot on the Black/Yellow wire
as a guide as shown.

•

Discard the connectors.

•

Strip the harness casing back 30mm from the
tip of the Black/White wire as shown taking
care not to damage the wire casing.

•

Strip the Black/White wire casing back 10mm
from the end of the wire as shown taking care
not to damage the wire.

•

Strip the Black/Yellow wire casing back 10mm
from the end of the wire as shown taking care
not to damage the wire.

CUT HERE

Page 3

Repair Procedure (Continued)
•

Insert one end of each of the same colored
wire into the repair harness butt splice.

REPAIR HARNESS SIDE

NOTE:
o Use an appropriate size crimper for the butt
splice.

BLACK/
YELLOW

o Splice specifications:
o JIS C 2806 : B1.25
o Wire Range (AWG) : 22 - 16

BLACK/
WHITE

o Barrel Outside Dia. : 3.3 mm
o Barrel Inside Dia.

: 1.7 mm

•

Crimp each butt splice securely.

•

Position one of the butt splices lengthwise in
the center of one of the protective sheets from
the repair kit as shown.

•

Repeat for the other butt splice.

•

Fold the protective sheet in half and press
firmly to make a protective seal around the
butt splice as shown.

•

Repeat for the other butt splice.

•

The two butt splices should be next to each
other with a folded over protective sheets as
shown.

•

Wrap the folded protective sheets around the
butt splices.

•
•

Wrap the entire repair with at least 2 layers of harness tape as shown.
Do not cover the gray tape [T] when wrapping the repair.

BEFORE WRAPPING WITH HARNESS TAPE
T

AFTER WRAPPING WITH HARNESS TAPE
T

Page 4

CRIMP THIS
SIDE ONLY

Repair Procedure (Continued)
•

Fold the horn harness as shown so the
existing gray tape [T] is positioned next to the
butt splices [B] as shown.

T

B

•

Position the horn harness [H] alongside the
main harness [M] as shown and hold them in
this position in preparation for the next step.
M
H

•

Pass the harness through the guide [G] and
position the gray tape [T] so that it rests
against the guide.

T
G

•
•
•
•

Make sure that band [1] is centered over the
gray tape.
Install band [2] approximately 1.5 inches from
band [1].
Install band [3] approximately 1.5 inches from
band [2].
Tighten all three bands.

1

2

NOTE:
o Do not secure the harness to the guide. The
harness must be free to move alongside the
guide.
•

•

•
•
•

Connect the shorter horn harness lead to
upper [U] connector of the horn. Be sure
boot opening is facing down.
Connect the longer horn harness lead to
lower [L] connector of the horn. Be sure
boot opening is facing down.
Connect the negative battery cable.
Test the horn.
Install all removed parts.

the
the

U

the
the
L

Page 5

3

Warranty Information
This is a Factory Directed Modification. 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.

Repair Horn Harness
Job Code

21407

Flat Rate Time

0.3 hr

Claim Type

3

Part Number

99999-0771

Description

Kit, Horn Harness

Quantity

1

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.

Repair Verification
The three bands, along with the harness repair,
will 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.

BEFORE

AFTER

Page 6

2019 & 2020 NINJA® ZX™-6R, -6R ABS & -6R ABS KRT EDITION
HORN HARNESS REPLACEMENT

FACTORY DIRECTED MODIFICATION
Dear Kawasaki Motorcycle Owner:
At Kawasaki, we take pride in producing high quality products and are committed to your continued satisfaction. To
maintain these standards, we have launched a service campaign to address a condition present on your motorcycle.
What is the reason for this notice?
On affected units, the horn harness can break due to engine vibration resulting in an inoperative horn. 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 horn harness. The actual repair will take up to 30 minutes but may
take longer due to scheduling at the dealership and the time needed to obtain required parts.
What should you do?
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.
Can we assist you further?
If you have questions or concerns that your dealer is not able to resolve, please contact Kawasaki’s Customer Care
Department 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.
Can we assist you further?
Our records indicate you are the current owner of the 2019 & 2020 Ninja® ZX™-6R, -6R ABS & -6R ABS KRT Edition
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.
Thank you for your purchase of a Kawasaki product and we hope that this campaign will maintain your continued
satisfaction.
Sincerely,
Kawasaki Motors Corp., U.S.A.

Page 7