MC20-08 Service Bulletin/Repair Instructions

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

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