Kawasaki recalls

On eligible units of 2025 & 2026 W230 (BJ230A) and Meguro S1 (BJ230B) models the turn signal bulbs may fail prematurely due to an improper manufacturing process.

Fix: To overcome this problem Kawasaki has initiated a recall campaign to replace the front and rear turn signal bulbs.

Vehicle count not given · built 1 Jan 2025 to 25 Jun 2026

On eligible units of 2025 & 2026 W230 (BJ230A) and Meguro S1 (BJ230B) models the turn signal bulbs may fail prematurely due to an improper manufacturing process.

Fix: To overcome this problem Kawasaki has initiated a recall campaign to replace the front and rear turn signal bulbs.

50 vehicles · built 1 Jan 2025 to 25 Jun 2025

On affected motorcycles the crankcase fastening bolts may have been over-tightened during production. This can cause seizure of the crankshaft main bearing leading to abnormal noise and engine stalling.

Fix: Check crankshaft main bearing and retighten the crankcase fastening bolts.

649 vehicles · built 31 Jul 2023 to 19 Jun 2025

The crankcase fastening bolts may have been over-tightened during production. This can cause seizure of the crankshaft main bearing leading to abnormal noise and engine stalling.

Fix: Check crankshaft main bearing and retighten the crankcase fastening bolts.

594 vehicles · built 31 Jul 2023 to 28 May 2025

On affected motorcycles the clutch release shaft was not properly welded to the lever due to an improper manufacturing process.

Fix: Replace the clutch release shaft.

10 vehicles · built 22 Jan 2024 to 24 Jan 2024

On affected motorcycles there is a risk the terminals of the motor drive battery packs may become dislodged during plugging or unplugging of the battery packs due to a manufacturing error.

Fix: Inspect and replace battery packs if necessary.

39 vehicles · built 3 Jul 2023 to 30 Oct 2023

On affected motorcycles there is a risk the terminals of the motor drive battery packs may become dislodged during plugging or unplugging of the battery packs due to a manufacturing error.

Fix: Inspect and replace battery packs if necessary.

36 vehicles · built 4 Jul 2023 to 8 Aug 2023

On affected machines there is a risk that the motorcycle may shift to neutral when the rider attempts to shift from 1st to 2nd gear due to improper programming of the shift control system.

Fix: Update the shift control system with modified software.

44 vehicles · built 21 Nov 2023 to 30 May 2024

On affected machines there is a risk that the motorcycle may shift to neutral when the rider attempts to shift from 1st to 2nd gear due to improper programming of the shift control system.

Fix: Update the shift control system with modified software.

44 vehicles · built 2 Feb 2024 to 31 May 2024

The spark plugs may have been damaged during the manufacturing process. Continued use in this condition may result in unstable idle and in the worst case lead to the engine stalling.

Fix: To overcome this problem Kawasaki will replace the spark plugs.

149 vehicles · built 13 Jul 2023 to 28 Oct 2023

The spark plugs may have been damaged during the manufacturing process. Continued use in this condition may result in unstable idle and in the worst case lead to the engine stalling.

Fix: To overcome this problem Kawasaki will replace the spark plugs.

100 vehicles · built 15 Jul 2023 to 7 Nov 2023

The plunger in the camshaft-chain tensioner can lock up during usage due to deterioration of internal parts.

Fix: Replace the camshaft chain tensioner with a revised part.

2,290 vehicles · built 1 Jan 2017 to 31 Dec 2022

The plunger in the camshaft-chain tensioner can lock up during usage due to deterioration of internal parts.

Fix: Replace the camshaft chain tensioner with a revised part.

2,290 vehicles · built 1 Jan 2016 to 31 Dec 2022

The plunger in the camshaft-chain tensioner can lock up during usage due to deterioration of internal parts.

Fix: Replace the camshaft chain tensioner with a revised part.

2,290 vehicles · built 1 Jan 2019 to 31 Dec 2022

On eligible units and models an improper control programme in the multi-function meter may exist.

Fix: Reprogramme the multi-function meter.�

175 vehicles · built 26 Nov 2021 to 23 Aug 2022

On eligible units and models an improper control programme in the multi-function meter may exist.

Fix: Reprogramme the multi-function meter.�

175 vehicles · built 20 Oct 2021 to 22 Jul 2022

The wiring harness for the horn may not be durable enough.�

Fix: Replace the horn and bracket on all units and to modify the wiring harness.

388 vehicles · built 9 Jan 2019 to 14 Feb 2022

The wiring harness for the horn may not be durable enough.�

Fix: Replace the horn and bracket on all units and to modify the wiring harness.

388 vehicles · built 9 Jan 2019 to 14 Feb 2022

The wiring harness for the horn may not be durable enough.�

Fix: Replace the horn and bracket on all units and to modify the wiring harness.

388 vehicles · built 9 Jan 2019 to 14 Feb 2022

The wiring harness for the horn may not be durable enough.�

Fix: Replace the horn and bracket on all units and to modify the wiring harness.

388 vehicles · built 9 Jan 2019 to 14 Feb 2022

The exhaust pipe might be incorrectly secured.

Fix: Replace the exhaust collars and gaskets and tighten the nuts with a new sequence and a higher torque.

92 vehicles · built 20 May 2019 to 28 Apr 2021

The exhaust pipe might be incorrectly secured.

Fix: Replace the exhaust collars and gaskets and tighten the nuts with a new sequence and a higher torque.

92 vehicles · built 20 May 2019 to 28 Apr 2021

The exhaust pipe might be incorrectly secured.

Fix: Replace the exhaust collars and gaskets and tighten the nuts with a new sequence and a higher torque.

92 vehicles · built 20 May 2019 to 28 Apr 2021

The amount of grease applied to the needle-bearings in the rear hub housing may be insufficient.

Fix: Replace the rear hub housing needle bearing on all eligible units.

1,042 vehicles · built 1 Dec 2017 to 9 Apr 2020

The oil pressure relief valve may fail resulting in low oil pressure.

Fix: Replace the oil pressure relief valve.

209 vehicles · built 2 Dec 2020 to 27 Apr 2021

The amount of grease applied to the needle-bearings in the rear hub housing may be insufficient.

Fix: Replace the rear hub housing needle bearing on all eligible units.

1,042 vehicles · built 1 Dec 2017 to 9 Apr 2020

The oil pressure relief valve may fail resulting in low oil pressure.

Fix: Replace the oil pressure relief valve.

209 vehicles · built 2 Dec 2020 to 27 Apr 2021

The oil pressure relief valve may fail resulting in low oil pressure.

Fix: Replace the oil pressure relief valve.

209 vehicles · built 2 Dec 2020 to 27 Apr 2021

The oil pressure relief valve may fail resulting in low oil pressure.

Fix: Replace the oil pressure relief valve.

209 vehicles · built 2 Dec 2020 to 27 Apr 2021

The oil pressure relief valve may fail resulting in low oil pressure.

Fix: Replace the oil pressure relief valve.

209 vehicles · built 2 Dec 2020 to 27 Apr 2021

The amount of grease applied to the needle-bearings in the rear hub housing may be insufficient.

Fix: Replace the rear hub housing needle bearing on all eligible units.

1,042 vehicles · built 1 Dec 2017 to 9 Apr 2020

The electronic control unit (ECU) doesn�t control the sudden increase in engine rpm if the transmission gear is not properly engaged

Fix: Reprogramme the ECU on all eligible units to control the sudden rpm surge.

892 vehicles · built 1 Dec 2017 to 7 Nov 2019

The electronic control unit (ECU) doesn�t control the sudden increase in engine rpm if the transmission gear is not properly engaged

Fix: Reprogramme the ECU on all eligible units to control the sudden rpm surge.

892 vehicles · built 1 Dec 2017 to 7 Nov 2019

The electronic control unit (ECU) doesn�t control the sudden increase in engine rpm if the transmission gear is not properly engaged

Fix: Reprogramme the ECU on all eligible units to control the sudden rpm surge.

892 vehicles · built 1 Dec 2017 to 7 Nov 2019

The wiring harness for the horn may not be durable enough and could break.

Fix: Modify the wiring harness

484 vehicles · built 3 Jul 2018 to 18 Jun 2019

The factory Electronic Control Unit programming may cause the engine to after fire when Kawasaki Quick Shifter is used under heavy engine load.

Fix: Reprogram the ECU. Replace the reed valves in the air suction valve assemblies on used motorcycles and if necessary replace any parts that have been heat damaged as a result of after-fire occurring.

238 vehicles · built 2 Oct 2018 to 27 Jun 2019

The factory Electronic Control Unit programming may cause the engine to after fire when Kawasaki Quick Shifter is used under heavy engine load.

Fix: Reprogram the ECU. Replace the reed valves in the air suction valve assemblies on used motorcycles and if necessary replace any parts that have been heat damaged as a result of after-fire occurring.

238 vehicles · built 2 Oct 2018 to 27 Jun 2019

The factory Electronic Control Unit programming may cause the engine to after fire when Kawasaki Quick Shifter is used under heavy engine load.

Fix: Reprogram the ECU. Replace the reed valves in the air suction valve assemblies on used motorcycles and if necessary replace any parts that have been heat damaged as a result of after-fire occurring.

238 vehicles · built 2 Oct 2018 to 27 Jun 2019

The steering shaft may not have been correctly aligned with the steering gear during production.

Fix: Replace the steering shaft and pinch bolt.

2,037 vehicles · built 8 Dec 2015 to 16 Dec 2019

There is a possibility that the oil passage holes in the oil filter housing have not been correctly machined.

Fix: If the oil passage holes have not been correctly machined the engine assembly will be replaced.

459 vehicles · built 3 Sep 2018 to 22 Jan 2019

There is a possibility that the oil passage holes in the oil filter housing have not been correctly machined.

Fix: If the oil passage holes have not been correctly machined the engine assembly will be replaced.

459 vehicles · built 3 Sep 2018 to 22 Jan 2019

Risk of fire due to possible oil cooler pipes and fuel cap leaks.

Fix: Replacement of oil cooler pipes and fuel filler cap.

134 vehicles · built 1 Jul 2018 to 31 Dec 2018

Due to incorrect routing the rear brake hose and / or the rear wheel rotation sensor lead may touch the rear tyre.

Fix: Inspect and re-route the hose and lead as needed replace the rear brake hose and / or sensor lead if they are damaged.

341 vehicles · built 1 Aug 2017 to 13 Nov 2017

Due to incorrect routing the rear brake hose and / or the rear wheel rotation sensor lead may touch the rear tyre.

Fix: Inspect and re-route the hose and lead as needed replace the rear brake hose and / or sensor lead if they are damaged.

341 vehicles · built 1 Aug 2017 to 13 Nov 2017

Due to incorrect routing the rear brake hose and / or the rear wheel rotation sensor lead may touch the rear tyre.

Fix: Inspect and re-route the hose and lead as needed replace the rear brake hose and / or sensor lead if they are damaged.

341 vehicles · built 1 Aug 2017 to 13 Nov 2017

Improper welding of the spring mounting pin to the left side centre stand mounting bracket may cause a failure allowing the centre stand spring to fall off.

Fix: On affected vehicles replace the left centre stand bracket.

378 vehicles · built 1 Dec 2017 to 30 May 2018

The strength of some gears in the transmission may not be sufficient and could break if they receive excessive impact force during shifting. Drive could be lost and In the worst case the transmission may lock.

Fix: On affected machines replace the 2nd 3rd and 4th output gears and the 2nd input gear

1,064 vehicles

The strength of some gears in the transmission may not be sufficient and could break if they receive excessive impact force during shifting. Drive could be lost and In the worst case the transmission may lock.

Fix: On affected machines replace the 2nd 3rd and 4th output gears and the 2nd input gear

1,064 vehicles

The holes in the rear shock absorber tie-rod frame mounts can become elongated if the rear shock absorber bottoms out. This could cause the tie rod installation bracket to break.

Fix: Inspect the frame for damage and fit additional bracing brackets to the frame. In rare cases the frame may need to be replaced.

671 vehicles

The holes in the rear shock absorber tie-rod frame mounts can become elongated if the rear shock absorber bottoms out. This could cause the tie rod installation bracket to break.

Fix: Inspect the frame for damage and fit additional bracing brackets to the frame. In rare cases the frame may need to be replaced.

671 vehicles

On affected machines carburettor float may stick causing a fuel leak.

Fix: Inspect and if necessary modify the carburettor.

109 vehicles · built 1 Jan 2015 to 31 May 2017

On affected machines fuel may leak from the fuel tap when it is operated.

Fix: Installation of a new fuel tap.

280 vehicles

On affected machines fuel may leak from the fuel tap when it is operated.

Fix: Installation of a new fuel tap.

280 vehicles

On affected machines carburettor float may stick causing a fuel leak.

Fix: Inspect and if necessary modify the carburettor.

109 vehicles · built 1 Jan 2015 to 31 May 2017

On affected machines carburettor float may stick causing a fuel leak.

Fix: Inspect and if necessary modify the carburettor.

109 vehicles · built 1 Jan 2015 to 31 May 2017

On affected machines fuel may leak from the fuel tap when it is operated.

Fix: Installation of a new fuel tap.

280 vehicles

On affected machines fuel may leak from the fuel tap when it is operated.

Fix: Installation of a new fuel tap.

280 vehicles

On affected machines fuel may leak from the fuel tap when it is operated.

Fix: Installation of a new fuel tap.

280 vehicles

Vibrations can cause the tail / brake light bulb socket to displace and come away from the lamp assembly.

Fix: On affected machines replace the light socket with a quality assured unit.

96 vehicles · built 1 Jan 2017 to 31 May 2017

A foreign object could puncture the front floor cover which can present a risk to the vehicle occupants.

Fix: Recall the machines that are likely to be affected and fit additional reinforcement to the floor.

345 vehicles · built 1 Dec 2015 to 31 May 2016

The steering damper mounting bracket bolts may have been over tightened during production. This can lead to one or both bolts breaking which may allow the bracket to interfere with the steering.

Fix: Recall the machines that are likely to be affected and replace both bolts with new ones.

310 vehicles

The wiring harness under the fuel tank may be damaged from contact with the frame edge. This can lead to a short circuit and the engine stalling. In addition on all 2011-2012 models and some 2013 models the throttle body holders may harden and crack in use due to insufficient heat resistance. This can lead to rough engine performance.

Fix: Recall the machines that are likely to be affected to inspect and where necessary repair the wiring loom. A guard will be fitted over the loom which may also have to be rerouted to prevent further contact. For applicable units the throttle body holders will also be replaced with improved ones.

899 vehicles

When the engine is cold it may stall when coasting under deceleration. This could increase the risk of an incident.

Fix: Recall the machines that are likely to be affected and update the software in the Electronic Control Unit (ECU).

364 vehicles

When the engine is cold it may stall when coasting under deceleration. This could increase the risk of an incident.

Fix: Recall the machines that are likely to be affected and update the software in the Electronic Control Unit (ECU).

364 vehicles

The insulation on the ignition switch harness may rub on the underside of the fuel tank. This can lead to an electrical short which may cause the engine to stall and increase the risk of injury to the rider pillion and other road users.

Fix: Recall the machines that are likely to be affected and inspect the ignition wiring located under the fuel tank. Where necessary the ignition switch (wiring attached) will be replaced. A wiring protection kit will be installed on all machines.

128 vehicles

The rear suspension unit has a possible assembly defect in that the piston-shaft nut has in some cases not been correctly tightened. If a defective suspension unit is fitted there could be an oil leak or a loss of damping control which can adversely affect the handling of the machine.

Fix: The owner is given a web-address to follow and access the necessary information to acertain if the shock absorber is definately affected and what to do if it is in the affected range. If your shock absorber is affected by the recall please contact the �hlins distributor in your country for an appointment to have your shock absorber corrected.

12 vehicles

During extreme operating conditions high temperature or high humidity climates it is possible that the insulation on the spark plug cap may breakdown. This can result in either electrical leakage and a misfire. However in extreme cases this can cause the engine to stall.

Fix: Recall all affected machines and replace the spark plug.

426 vehicles

The fuel tank may be deformed by the influence of varying temperature conditions fuel used and material thickness. Such deformation could cause a leak at the fuel tap mounting area leading to a potential fire risk.

Fix: Recall the machines that are likely to be affected to replace the fuel tank and fuel tap O ring

2 vehicles

The ABS system may not function correctly causing longer stopping distances than expected and also the fault may not illuminate the ABS warning lamp. This is due to a none conformance on production with the ABS unit.

Fix: Recall the machines that are likely to be affected and replace the ABS unit.

50 vehicles

It is possible that an internal fault in the engine Electronic Control Unit (ECU) may cause the engine to stall. This can lead to a loss of control of the machine.

Fix: Recall all affected machines and replace the engine ECU with a reprogrammed unit.

311 vehicles

The ABS system may not function correctly causing longer stopping distances than expected and also the fault may not illuminate the ABS warning lamp. This is due to a none conformance on production with the ABS unit.

Fix: Recall the machines that are likely to be affected and replace the ABS unit.

50 vehicles

The engine may stall due to premature wear of a bearing in the fuel pump. Prior to failure an abnormal noise will occur and continued use of the machine in this condition could lead to decreased engine power and eventual failure of the bearing.

Fix: Recall the machines that are likely to be affected to replace the fuel pump with a new one.

504 vehicles

On eligible units of Ninja ZX-10R and Ninja ZX-10R ABS models some engine crankcases may have a casting flaw which allows engine oil to leak at the starter motor mounting area and collect on the crankcase surface. Continued use in this condition can allow oil to get onto the rear tyre

Fix: The repair consists of adding a special sealing compound to the affected area to avoid any possibility of oil leakage.

816 vehicles

On eligible units of 1400 GTR and 1400GTR ABS models small stones or other road debris can become trapped between the rear brake pedal and guard and prevent the pedal from fully releasing. This can cause over heating potentially leading to rear brake damage and lock up or failure of the rear brake. On 14 GTR ABS models with K-ACT the front brake may also be affected because it is linked with rear brake operation.

Fix: The repair consists of replacing the rear master cylinder rod end and removing the guard.

1,476 vehicles

The operation of the vehicle down sensor under certain conditions may be affected by vibration through it's mounting and cause the engine to cut out.

Fix: Recall the machines that are likely to be affected to replace the mounting of the down sensor.

1,795 vehicles

The circlips securing the passenger footrest pivot may be brittle due to a manufacturing error. This can cause the circlip to fail allowing the pivot pins to come out of position and the footrest to come off while riding creating the potential for an accident.

Fix: Replacement of circlips on both passenger footrests.

219 vehicles

The circlips securing the passenger footrest pivot may be brittle due to a manufacturing error. This can cause the circlip to fail allowing the pivot pins to come out of position and the footrest to come off while riding creating the potential for an accident.

Fix: Replacement of circlips on both passenger footrests.

219 vehicles

The circlips securing the passenger footrest pivot may be brittle due to a manufacturing error. This can cause the circlip to fail allowing the pivot pins to come out of position and the footrest to come off while riding creating the potential for an accident.

Fix: Replacement of circlips on both passenger footrests.

219 vehicles

The circlips securing the passenger footrest pivot may be brittle due to a manufacturing error. This can cause the circlip to fail allowing the pivot pins to come out of position and the footrest to come off while riding creating the potential for an accident.

Fix: Replacement of circlips on both passenger footrests.

219 vehicles

It is possible that the fuel pump bracket may have been installed incorrectly. This can cause the fuel hose to chaff on the air box resulting in damage to the hose and a possible fuel leak.

Fix: Recall all the affected vehicles for inspection and if required the repositioning of the bracket plus the replacement of the fuel hose.

34 vehicles

It is possible for the regulator circuit board to get too hot which will lead to uncontrolled charging current output. This can cause discharge of the battery which may result in difficult starting or in some circumstances engine stall while riding creating the potential for an accident.

Fix: Recall the machines which are likely to be affected to replace the regulator.

3,656 vehicles

It is possible for the regulator circuit board to get too hot which will lead to uncontrolled charging current output. This can cause discharge of the battery which may result in difficult starting or in some circumstances engine stall while riding creating the potential for an accident.

Fix: Recall the machines which are likely to be affected to replace the regulator.

3,656 vehicles

The main wiring harness can can rub against the rear of the motorcycle frame this can cause the engine to stop running and leave the rider in a vunerable situation.

Fix: Recall vehicles to inspect and re-route harness if harness damaged this will be repaired or replaced.

628 vehicles

During the manufacturing process the inner tubes may be pinched and in the worst case holed. This could cause tyre deflation and creates an increased risk the rider could lose control of the machine.

Fix: Recall the machines that are likely to be affected to check and where necessary replace the inner tubes.

86 vehicles

During the manufacturing process the inner tubes may be pinched and in the worst case holed. This could cause tyre deflation and creates an increased risk the rider could lose control of the machine.

Fix: Recall the machines that are likely to be affected to check and where necessary replace the inner tubes.

86 vehicles

The mounting brackets on the side of the fuel tank may crack due to stress while riding this can cause a fuel leak.

Fix: Check mounting for cracks and damper clearance. If the fuel tank is leaking replacing of the tank is required. In all cases fit correct sized fuel tank damper.

555 vehicles

When the machine is used in wet conditions (or when washing) water may enter the ECU or vehicle down sensor connections through the wiring harness. This can lead to corrosion on the terminals. Also the wiring for the fuel injection may rub on the frame wearing the insulation away. Both of these situations may cause the engine to cut out creating the potential for an accident.

Fix: Check ECU down sensor and harness for damage and replace items if required.

555 vehicles

The engine ECU may have the incorrect settings installed which could cause the engine to stall and cause the rider to loose control of the machine.

Fix: Recall all affected machines and change the engine ECU.

270 vehicles

The foot may be impeded when operating the rear brake operating lever effectively by the top edge of the lower cowling. This could cause longer than expected stopping distances.

Fix: Recall the machines that are likely to be affected to replace the right hand foot guard and lower cowling bracket.

1,613 vehicles

The left front brake hose may contact the brake disc during extremely heavy braking. This can damage the hose and lead to a fluid leak which could cause brake failure and result in an accident.

Fix: Recall the machines that are likely to be affected to check and where necessary replace the left front brake hose and install a brake hose damper.

694 vehicles · built 5 Oct 2009 to 31 May 2010

Oil may leak from the rear shock absorber which may get on the rear tyre and cause a lack of adhesion tyre to road.

Fix: Recall the machines that are likely to be affected to fit a new shock absorber.

210 vehicles

Porosity of the engine upper case could allow oil to leak which may get on to rear tyre leading to the potential for an accident

Fix: Recall affected machines check upper case for leaks and replace relevant parts if necessary.

51 vehicles

On a small percentage of bicycles the chain slips for a brief period then catches again. No incidents have occurred.

Fix: As a safety precaution all bicycles were removed from sale and are being reworked by manufacturer.

1,628 vehicles · built 1 Mar 2009 to 30 Apr 2009

On a small percentage of bicycles the chain slips for a brief period then catches again. No incidents have occurred.

Fix: As a safety precaution all bicycles were removed from sale and are being reworked by manufacturer.

1,628 vehicles · built 1 Mar 2009 to 30 Apr 2009

It has been identified that under certain riding conditions a small stone thrown up from the road surface may become trapped between the rear brake master cylinder operating rod and the rear brake pedal. This can prevent the rear brake from fully releasing causing it to drag and overheat. This eventually can cause the rear wheel to lock resulting in possible loss of control.

Fix: Recalled machines will be fitted with a brake pedal protective cover.

752 vehicles

It has been identified that under certain riding conditions fuel can leak from between the tank filler neck and the fuel cap gasket. Fuel leakage in the presence of a spark or a flame may result in an explosion or a fire.

Fix: Recalled machines will have the fuel tank replaced.

105 vehicles

It is possible that the engine mounting adjustment collars have been over tightened during production. In the affected machines in certain circumstances it is possible for the frame lower cross pipe to crack and if left unattended the cross pipe could separate resulting in the potential for an accident.

Fix: Recall the machines that are likely to be affected to check the torque of the engine mounting collars and where necessary retorque them. If the mountings have been over tightened the engine mounting frame will have to be removed for inspection and replaced where necessary.

1,239 vehicles

It is possible that the engine mounting adjustment collars have been over tightened during production. In the affected machines in certain circumstances it is possible for the frame lower cross pipe to crack and if left unattended the cross pipe could separate resulting in the potential for an accident.

Fix: Recall the machines that are likely to be affected to check the torque of the engine mounting collars and where necessary retorque them. If the mountings have been over tightened the engine mounting frame will have to be removed for inspection and replaced where necessary.

1,239 vehicles

It is possible that the engine mounting adjustment collars have been over tightened during production. In the affected machines in certain circumstances it is possible for the frame lower cross pipe to crack and if left unattended the cross pipe could separate resulting in the potential for an accident.

Fix: Recall the machines that are likely to be affected to check the torque of the engine mounting collars and where necessary retorque them. If the mountings have been over tightened the engine mounting frame will have to be removed for inspection and replaced where necessary.

1,239 vehicles

It is possible that the engine mounting adjustment collars have been over tightened during production. In the affected machines in certain circumstances it is possible for the frame lower cross pipe to crack and if left unattended the cross pipe could separate resulting in the potential for an accident.

Fix: Recall the machines that are likely to be affected to check the torque of the engine mounting collars and where necessary retorque them. If the mountings have been over tightened the engine mounting frame will have to be removed for inspection and replaced where necessary.

1,239 vehicles

It has been identified that on subject machines the fuel hose may not have been properly connected to the fuel injector delivery pipe creating the possibility of a fuel leak resulting in the risk of fire or an explosion.

Fix: Recalled machines will be inspected to ensure that the fuel hose has been properly secured to the fuel rail. The fuel hose will be replaced if the clip is damaged and will not lock correctly.

560 vehicles

In certain circumstances it is possible that the genuine accessory luggage carrier could break. In the worst case the carrier and luggage could become detached from the motorcycle creating the potential for an accident.

Fix: Recall the machines that are likely to be affected to replace the luggage rack with one that has been newly designed and reinforced.

330 vehicles

In certain circumstances it is possible for the side case latch pivot pin to break. This could result in the side case/s becoming detached from the machine.

Fix: Recall the machines that are likely to be affected to replace the locks on both the left and right side cases.

397 vehicles

Under certain conditions the fuel tank may crack at the front and rear mounting tabs. This can allow fuel to leak causing the risk of fire.

Fix: Recall the machines that are likely to be affected and replace the fuel tank dampers and where necessary replace the fuel tank.

35 vehicles

It has been identified that the routing of the front brake hose may be incorrect as a result of manufacture or service due to an error in the service manual. This can cause the hose to contact the underside of the ignition switch body or the screw situated at the right hand side of the steering head. Continued use in this condition can lead to damage of the front brake hose with eventual leakage and resulting in the possibility of brake failure.

Fix: Recalled machines will have the front brake hose checked for routing position of the damper and condition. The hose damper will be repositioned as required and the hose replaced should this prove to be necessary.

147 vehicles

On some eligible units the signal lamp bracket may crack due to vibration and rough riding conditions. If this condition is not corrected the bracket with the attached license plate could become detached from the motorcycle creating a road hazard.

Fix: Recall the vehicles that are likely to be affected to replace the signal lamp bracket.

173 vehicles

The position of the spark plug may be deeper than standard which will result in various conditions from poor running to in the worst case engine failure.

Fix: Recall the vehicles that are likely to be affected to check the cylinder head Lot number and check the depth of the spark plug. Where the depth of the spark plug is incorrect it will be necessary to replace the cylinder head.

190 vehicles

The mounting bolts of the vehicle down sensor may loosen and in the worst case the down sensor may detach from the bracket causing the engine to stall whilst being ridden or the engine not to cut out in the event of a fall.

Fix: Recall the vehicles that are likely to be affected and tighten the down sensor mounting bolts to the specified torque.

258 vehicles

It is possible that the steering damper mounting bolt may not have been correctly tightened during assembly. If not found this could lead to the bolt loosening and the steering damper detaching from the bracket allowing it to possibly interfere with the steering and creating the potential for an accident.

Fix: Recall the vehicles that are likely to be affected to tighten the steering damper bolt to the correct torque and to check the play between the steering damper and bracket.

1,116 vehicles

The front steering knuckle clamp bolts may not have been tightened sufficiently.

Fix: Recall the vehicles that are affect (the vehicles that have had recall number RM/2005/030 completed prior to 03/03/2006) to inspect the steering knuckle clamp bolts and replace as necessary. Refit the clamp bolts and tighten to the correct torque.

61 vehicles

There is a possibility that the front lower suspension swivel joints may fracture. If this occurs steering control will be lost.

Fix: Recall the vehicles that are likely to be affected and replace both of the front lower suspension swivel joints.

141 vehicles

It has been identified thatthe steering tie rod ends could separate during operation due either to wear or impact leading to loss of steering control. Prior to each and every ride Kawasaki strongly recommends that you inspect the tie rods according to the inspection procedure. If free play is found the machine should not be ridden until such time as a repair has been carried out. If no free play is found the machine should not be ridden in adverse or rough conditions and or with a heavy load. Should you feel incapable of carrying out the inspection your Kawasaki dealer should be contacted for advice.

Fix: Recalled machines will have the steering tie rods replaced with quality assured parts.

76 vehicles

Electrical wiring may short circuit and cause the engine to cut out.

Fix: Recall the likely to be affected machines and reposition the ignition switch block connector to prevent the harness from being worn or cut.

286 vehicles

It has been established that a significant impact to either front wheel whilst the steering is on full lock can result in deformation of the steering ball joint mounting hole within the steering knuckle. Over time the ball joint can become loose in the knuckle and cause the mounting hole to wear. Continued use of the vehicle in this condition may eventually lead to separation of the ball joint resulting in suspension/steering failure and the potential for an accident.

Fix: It is the intention to recall all likely to be affected machines and change the subject steering components. However before this is done Kawasaki will inform owners of the need to check the suspension and steering before riding the machine and comprehensive instructions on how to do this are to be issued. It should be noted that if any free play is found within the steering knuckle the machine should not be ridden until such time as the re-work is carried out.

2,116 vehicles · built 1 Jan 2001 to 26 Jul 2005

It has been established that a significant impact to either front wheel whilst the steering is on full lock can result in deformation of the steering ball joint mounting hole within the steering knuckle. Over time the ball joint can become loose in the knuckle and cause the mounting hole to wear. Continued use of the vehicle in this condition may eventually lead to separation of the ball joint resulting in suspension/steering failure and the potential for an accident.

Fix: It is the intention to recall all likely to be affected machines and change the subject steering components. However before this is done Kawasaki will inform owners of the need to check the suspension and steering before riding the machine and comprehensive instructions on how to do this are to be issued. It should be noted that if any free play is found within the steering knuckle the machine should not be ridden until such time as the re-work is carried out.

2,116 vehicles · built 1 Jan 2005 to 26 Jul 2005

On some eligible units the shock absorber may have been fitted with an incorrect O-ring. This can resulted in a hydraulic oil leak and create the potential for an accident.

Fix: Affected machines will be recalled at which time the shock absorber will be replaced with a quality assured item.

9 vehicles

There is a possibility that the front brake hose could become wedged between the front fork and the fender. The brake hose may suffer abrasion damage.

Fix: Recall affected machines check brake hose replace if necessary and fit brake hose clamp

70 vehicles

There is a possibility that the front wheel could contain casting flaws which could potentially lead to failure.

Fix: Recall affected machines and replace front wheel.

1,192 vehicles

During cold starts the oil pressure relief valve may not respond quickly enough thus allowing excess pressure to build up causing the bottom of the oil filter to deform. This can cause oil to leak from the filter with the potential of a slip type accident.

Fix: Recall likely to be affected machines and fit a replacement oil filter.

97 vehicles

During cold starts the oil pressure relief valve may not respond quickly enough thus allowing excess pressure to build up causing the bottom of the oil filter to deform. This can cause oil to leak from the filter with the potential of a slip type accident.

Fix: Recall likely to be affected machines and fit a replacement oil filter.

97 vehicles

During cold starts the oil pressure relief valve may not respond quickly enough thus allowing excess pressure to build up causing the bottom of the oil filter to deform. This can cause oil to leak from the filter with the potential of a slip type accident.

Fix: Recall likely to be affected machines and fit a replacement oil filter.

97 vehicles

Carburettor accelerator pump diaphragm may break resulting in a fuel leak and possible risk of fire.

Fix: Replace the accelerator pump diaphragm.

28 vehicles

The plug welds that secure the muffler bracket to the muffler body can crack allowing the muffler to become loose in the bracket. After continued use the muffler could separate from the main exhaust pipe creating the potential for an accident resulting in injury.

Fix: Recall affected machines to check the bracket welds and to add a damper or if necessary replacing the muffler.

2,628 vehicles

Carburettor accelerator pump diaphragm may swell and in the worst case break resulting in a fuel leak and possible risk of fire.

Fix: Recall affected machines and repace diaphragm.

7 vehicles

If excessive pressure is applied to the brake pedal the brake actuating cam mounted in the rear brake hub may fracture. This will result in failure of the rear brake.

Fix: Fit a modified rear brake operating cam shaft.

442 vehicles · built 1 Apr 2000 to 1 Apr 2003

It is possible for oil to seep through the electrical harness connected to the stator. In such a situation it may be possible for small amounts of oil to leak from the harness' upper connector. In extreme cases there is a small possibility that oil may make contact with the rear tyre. This may createa loss of control of the motorcycle.

Fix: Seal the electrical harness connected to the stator.

2,401 vehicles

A section of the main harness located under the back of the fuel tank can be rubbed by the metal clamp securing the fuel pump leads. Abrasion of the main harness sheath and the wire insulation caused by the clamp can lead to a malfunction of the turn signals instrument illumination or warning.

Fix: The repair consists of checking and repairing the main harness if required changing the bending direction of the clamp to the opposite side to eliminate contact with the main harness and then fixing the fuel pump leads securely with a tie band.

179 vehicles · built 1 Jan 2001 to 31 Dec 2002

The tyre valve nut on the front and rear wheels can crack from a combination of stress and corrosion. Because the affected units are fitted tubeless tyres cracking of the nut can lead to a reduction of tyre pressure. This could adversely affect the handling and performance of the vehicle and may create a risk of an accident possibly resulting in personal injury.

Fix: Fit replacement tyre valve nuts of increased size and improved material. Replace washer beneath the valve nut with one of improved material.

1,871 vehicles

The tyre valve nut on the front and rear wheels can crack from a combination of stress and corrosion. Because the affected units are fitted tubeless tyres cracking of the nut can lead to a reduction of tyre pressure. This could adversely affect the handling and performance of the vehicle and may create a risk of an accident possibly resulting in personal injury.

Fix: Fit replacement tyre valve nuts of increased size and improved material. Replace washer beneath the valve nut with one of improved material.

1,871 vehicles

A section of the wiring harness located above the headlight is incorrectly routed. The wiring harness may become damaged and this may result in a short circuit which can in turn lead to a malfunction of the turn signals and instrument lights.

Fix: Recall the affected Motorcycles inspect the wiring harness and where appropriate repair to the harness in any damaged areas. Additionally the wiring harness will be rerouted to prevent this potential problem occurring in the future.

186 vehicles

The overflow drainpipe inside the fuel tank may crack and leak fuel with a subsequent fire risk.

Fix: Recall affected machines and replace the fuel tank if the pipe is found to be cracked. Where the pipe is found to be serviceable a damper weight will be fitted to eliminate the vibration which may cause the pipe to crack. At the same time a new fuel level sensor will be fitted to address reports of inaccurate reading of the fuel gauge.

1,843 vehicles

The protective sleeve on the fuel hose from the fuel filter to the throttle assembly may not prevent damage to the hose by rubbing against the fuel pump plate. A fuel leak might occur with a risk of fire.

Fix: Recall affected motorcycles to replace the fuel hose with a modified type.

50 vehicles · built 1 Jan 1999 to 31 Dec 1999

The centre stand bolt may loosen and fall out if the centre stand is frequently used. This may cause the stand to bend resulting in contact with the drive chain or rear wheel. In extreme circumstances the stand could become displaced which may cause the rider to lose control of the motorcycle.

Fix: Recall affected machines to add locking plates and longer centre stand bolts. Renew the centre stand if it is damaged.

903 vehicles

Some machines may have been fitted with an incorrectly machined fourth gear dog. This could cause breakage of the gear dog and result in lock up of the transmission.

Fix: Affected machines are being recalled to have a check carried out on the machining of the fourth gear dog. Where this is found to be of the incorrect type the appropriate gears will be replaced.

48 vehicles · built 1 Jan 1997 to 31 Dec 1997

As a result of incorrect heat treatment the drive chain may crack and ultimately fail. This campaign includes some machines already actioned under recall RM95/2 which may have been fitted with incorrect chains at that time.

Fix: Recall the affected machines and replace the drive chain with a quality assured version.

644 vehicles

As a result of incorrect heat treatment the drive chain may crack and ultimately fail. This campaign includes some machines already actioned under recall RM95/2 which may have been fitted with incorrect chains at that time.

Fix: Recall the affected machines and replace the drive chain with a quality assured version.

644 vehicles

As a result of incorrect heat treatment the drive chain may crack and ultimately fail. This campaign includes some machines already actioned under recall RM95/2 which may have been fitted with incorrect chains at that time.

Fix: Recall the affected machines and replace the drive chain with a quality assured version.

644 vehicles

As a result of incorrect heat treatment the drive chain may crack and ultimately fail. This campaign includes some machines already actioned under recall RM95/2 which may have been fitted with incorrect chains at that time.

Fix: Recall the affected machines and replace the drive chain with a quality assured version.

644 vehicles

As a result of incorrect heat treatment the drive chain may crack and ultimately fail. This campaign includes some machines already actioned under recall RM95/2 which may have been fitted with incorrect chains at that time.

Fix: Recall the affected machines and replace the drive chain with a quality assured version.

644 vehicles

As a result of incorrect heat treatment the drive chain may crack and ultimately fail. This campaign includes some machines already actioned under recall RM95/2 which may have been fitted with incorrect chains at that time.

Fix: Recall the affected machines and replace the drive chain with a quality assured version.

644 vehicles

1) As a result of incorrect heat treatment the drive chain may crack and ultimately fail. 2) Items or tools placed in the document/tool kit compartment may fall from the compartment into the drive chain area. (ZX600 - F1 model only).

Fix: Recall the affected machines and:- A) Replace the drive chain with a quality assured version. B) Replace the tool bag and mounting strap with modified versions and fit an additional cover (ZX600-F1 model only).

1,075 vehicles

1) As a result of incorrect heat treatment the drive chain may crack and ultimately fail. 2) Items or tools placed in the document/tool kit compartment may fall from the compartment into the drive chain area. (ZX600 - F1 model only).

Fix: Recall the affected machines and:- A) Replace the drive chain with a quality assured version. B) Replace the tool bag and mounting strap with modified versions and fit an additional cover (ZX600-F1 model only).

1,075 vehicles

1) As a result of incorrect heat treatment the drive chain may crack and ultimately fail. 2) Items or tools placed in the document/tool kit compartment may fall from the compartment into the drive chain area. (ZX600 - F1 model only).

Fix: Recall the affected machines and:- A) Replace the drive chain with a quality assured version. B) Replace the tool bag and mounting strap with modified versions and fit an additional cover (ZX600-F1 model only).

1,075 vehicles · built 1 Jan 1994 to 31 Dec 1995

1) As a result of incorrect heat treatment the drive chain may crack and ultimately fail. 2) Items or tools placed in the document/tool kit compartment may fall from the compartment into the drive chain area. (ZX600 - F1 model only).

Fix: Recall the affected machines and:- A) Replace the drive chain with a quality assured version. B) Replace the tool bag and mounting strap with modified versions and fit an additional cover (ZX600-F1 model only).

1,075 vehicles · built 1 Jan 1994 to 31 Dec 1995

1) As a result of incorrect heat treatment the drive chain may crack and ultimately fail. 2) Items or tools placed in the document/tool kit compartment may fall from the compartment into the drive chain area. (ZX600 - F1 model only).

Fix: Recall the affected machines and:- A) Replace the drive chain with a quality assured version. B) Replace the tool bag and mounting strap with modified versions and fit an additional cover (ZX600-F1 model only).

1,075 vehicles · built 1 Jan 1994 to 31 Dec 1995

1) As a result of incorrect heat treatment the drive chain may crack and ultimately fail. 2) Items or tools placed in the document/tool kit compartment may fall from the compartment into the drive chain area. (ZX600 - F1 model only).

Fix: Recall the affected machines and:- A) Replace the drive chain with a quality assured version. B) Replace the tool bag and mounting strap with modified versions and fit an additional cover (ZX600-F1 model only).

1,075 vehicles · built 1 Jan 1994 to 31 Dec 1995

The front sprocket retaining nut may loosen due to incorrect installation of the locking washer. This could allow the sprocket to detach from the output shaft and possibly affect the stability of the machine.

Fix: Recall the affected machines for replacement of the front sprocket retaining nut and fitment of a revised locking washer.

3,148 vehicles · built 1 Jan 1989 to 31 Dec 1993

The front sprocket retaining nut may loosen due to incorrect installation of the locking washer. This could allow the sprocket to detach from the output shaft and possibly affect the stability of the machine.

Fix: Recall the affected machines for replacement of the front sprocket retaining nut and fitment of a revised locking washer.

3,148 vehicles · built 1 Jan 1989 to 31 Dec 1993

When the rear suspension is fully compressed the rear brake hose may chafe the rear brake disc. In consequence the brake hose may be damaged resulting in a possible loss of braking efficiency.

Fix: Recall affected machines for the fitment of modified brake hose clamps which will maintain clearance between the brake disc and hose with the suspension fully compressed. The rear brake hoses will be inspected for signs of chafing and replaced where t

750 vehicles · built 1 Jan 1991 to 31 Dec 1991