SERVICE
TITLE:

MC 24-05
March 1, 2024
Page 1 of 17

2024 Z e-1 ABS & NINJA® e-1 ABS Battery Lead Wire Replacement

FACTORY DIRECTED MODIFICATION
IMMEDIATE REPAIR REQUIRED
Eligibility

Kawasaki Action

Eligible Units
Year
2024

Model Name
Z e-1 ABS
NINJA e-1 ABS

Model Code
NR011ARFNN
NX011ARFNN

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 certain eligible units, the 12V battery lead wire
terminals may break off due to a faulty manufacturing
process.

Initiate Campaign:
Kawasaki has initiated an FDM campaign to replace
the positive and negative battery lead wires.
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 17 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.

©2024, Kawasaki Motors Corp., U.S.A.

Parts Information
Repair Kit Part Number:
INSTALL REPAIR KIT 99999-0933 ON ALL
ELIGIBLE UNITS.

NOTE:
o Use VIP in K-Dealer to identify affected units in
your dealership inventory to order repair kits for
unsold units.

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

Kit, Wire Lead, MC24-05, P/N 99999-0933

Parts Availability:
To ensure parts availability across the dealer
network, Kawasaki initially requests that parts are
ordered based on immediate demand:
• For retailed units, order parts as customers
schedule repairs or for repairs expected to
take place within the next two weeks.
• For unsold units, use VIP in K-Dealer to identify
the number of affected units in your dealership
inventory. Order repair parts only for units that
will be repaired for retail sale within the next
two weeks.

Contents
Wire-Lead, Positive
Wire-Lead, Negative
Tape

Qty
1
1
1

Recommended Tools & Consumables
•
•
•
•
•
•
•
•
•

8mm Socket
Wire Stripper
Wire Cutter
Razor Blade
Metric Ruler
Masking Tape
Vinyl Tape (Black)
White paint pen
5.5mm Non-Insulated Terminal Crimp Tool.
NOTE:
o The crimp tool required for this repair is not a common tool. Please purchase the following
approved tool. You will be reimbursed for the cost of the tool when you file the claim.
CLICK HERE TO ORDER FROM AMAZON

“Amazon and all related Marks are Trademarks of Amazon.com, Inc. or its affiliates.”

Page 2

Repair Procedure
Refer to service manual 99832-0282-02 (Z e-1 ABS) or 99832-0276-02 (NINJA e-1 ABS ) for detailed
information related to safety precautions, parts removal and parts installation.
•
•

Remove front and rear seats.
Remove and retain:
o Bolt [A]
o Bracket [B]
o Battery terminals [C] & [D]
o Battery [E]

•

Unclip fuse boxes [A], [B] & [C] to gain access
to the positive and negative battery lead wires.

•

Cover the left side of the frame and bodywork
with masking tape as shown.
Pull the battery lead wires from the vehicle as
shown.

•

•

Tape the positive battery lead [L] to the frame
to keep it out of the way temporarily.

L

Page 3

Repair Procedure (continued)

160mm

Replace Negative Lead Wire
• Mark the negative lead wire with a piece of
masking tape 160mm from the end of the
connector.

•

Carefully cut and peel back and remove
160mm of the vinyl tape [T] from negative lead
connector wire, making sure to avoid cutting
the underlying mesh wire loom [L].

T

L

NOTE:
16

o Be careful not to cut the mesh wire loom [L]
under the vinyl tape.

0m

m

CUT - PEEL - DISCARD 160mm VINYL TAPE

o
•

NOTE:
Do not cut the mesh wire loom.

N

Remove the negative lead wire [N] from the
mesh wire loom [L] taking care not to damage
the loom.

L

PEEL BACK MESH WIRE LOOM

Page 4

Repair Procedure (continued)
Replace Negative Lead Wire (continued)
• Align [A] new lead wire with original.
• Tape the new lead to the original lead.

•

ALIGN
CONNECTORS

Cut the original negative lead wire even with
the new connector as shown in the photo to
the right.

A

A

CUT LEAD
WIRES

NOTE:
o Be careful not to cut the mesh wire loom.

CUT HERE

Page 5

Repair Procedure (continued)
Replace Negative Lead Wire (continued)
• Measure 7mm from the end of the lead wire
and mark with a piece of tape.

7mm

NOTE:
o Be careful not to damage the copper wire when
stripping the insulation.

•

7mm

Strip 7mm insulation from lead wire.

STRIP
7MM

•
•

Insert the exposed wire into the connector of
the new lead wire.
Verify that there is a 1mm gap [G] between the
insulation and the connector.

G
1mm

•

Center [C] the crimp tool between the edge of
the connector and the dimple in the center of
the connector.

C
CENTER CRIMP TOOL HERE

Page 6

Repair Procedure (continued)
Replace Negative Lead Wire (continued)
• Crimp the new lead wire to the existing wire
with the 5.5 mm jaw.

•

CRIMP,
5.5mm

Pull on the lead wire on each side of the
connector to verify that the connection is
secure.

PULL TO TEST

•

SHORT

•

Place the sleeve connector on the center of
the tape (protector).
Refer to the photo to position the long and
short edges of the tape correctly.

LONG

•

Fold the tape in half and stick it together.
FOLD TAPE

Page 7

Repair Procedure (continued)
Replace Negative Lead Wire (continued)
• Wrap the tape [T] around the wire lead and
secure with a small piece of vinyl tape [V].

T
T
V

•

Insert the wire lead back inside the slotted
loom [L].

L

Page 8

Repair Procedure (continued)
Replace Negative Lead Wire (continued)
• Begin wrapping with vinyl tape 20mm from the
edge of the slotted loom.

20m