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December 9, 2022 NHTSA CAMPAIGN NUMBER: 22V912000
An engine stall while riding can increase the risk of a crash or injury.
NHTSA Campaign Number: 22V912
Manufacturer Kawasaki Motors Corp., U.S.A.
Components ENGINE AND ENGINE COOLING
Potential Number of Units Affected 3,172
Summary
Kawasaki Motors Corp., U.S.A. (KMC) is recalling certain 2015-2018 ZX1000, 2018 ZX1002A, ZX1002B, 2019-2021 ZX1002D, 2019-2022 ZX1002J, 2020-2023 ZR1000K, 2021-2022 ZR1000L, 2022 ZX1002R, and 2023 ZR1002L (Ninja H2, Ninja H2 Carbon, Ninja H2 SX, Ninja H2 SX SE, Ninja H2 SX SE+, Z H2, and Z H2 SE) motorcycles. Please see the attached model information chart for a detailed list of model codes, names and years. The plunger in the camshaft chain tensioner may lock, which can result in an engine stall while riding.
Remedy
Dealers will replace the camshaft chain tensioner, free of charge. Owner notification letters were mailed December 21, 2022. Owners may contact KMC customer service at 1-866-802-9381.
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.
REF: 22-22 MC
CODE: National
DATE: December 9, 2022
STOP RETAIL SALES & DELIVERY OF 2015~2023 Z H2, Z H2 SE, NINJA H2โข, NINJA H2โขR, NINJA H2โขCARBON, NINJA H2โขSX, NINJA H2โขSX SE & NINJA H2โขSX SE+
Year | Model Name | Model Code | Eligibility |
2015 | NINJA H2 NINJA H2R | ZX1000NFFL ZX1000PFF | Verify using VIP in K-Dealer. |
2016 | NINJA H2 NINJA H2R | ZX1000NGFL ZX1000PGF | |
2017 | NINJA H2
NINJA H2 CARBON NINJA H2 R | ZX1000XHFL
ZX1000XHFAL ZX1000YHF | |
2018 | NINJA H2
NINJA H2 CARBON NINJA H2 R NINJA H2 SX NINJA H2 SX SE | ZX1000XJFL
ZX1000XJFAL ZX1000YJF ZX1002AJF, ZX1002AJFL ZX1002BJF, ZX1002BJFL | |
2019 | NINJA H2
NINJA H2 CARBON NINJA H2 SX SE+ | ZX1002JKFL
ZX1002JKFAL ZX1002DKF, ZX1002DKFL | |
2020 | NINJA H2
NINJA H2 CARBON NINJA H2 R NINJA H2 SX SE+ Z H2 | ZX1002JLFL
ZX1002JLFAL ZX1000YLF ZX1002DLF, ZX1002DLFL ZR1000KLF , ZR1000KLFB, ZR1000KLFL | |
2021 | NINJA H2
NINJA H2 CARBON NINJA H2 R NINJA H2 SX SE+ Z H2 Z H2 SE | ZX1002JMFNL
ZX1002JMANL ZX1000YMFNN ZX1002DMFNL ZR1000KMFNL ZR1000LMFNL | |
2022 | NINJA H2
NINJA H2 CARBON NINJA H2 R NINJA H2 SX SE Z H2 Z H2 SE | ZX1002JNFNL
ZX1002JNANL ZX1000YNFNN ZX1002RNFNL ZR1000KNFAL ZR1000LNFNL | |
2023 | Z H2
Z H2 SE | ZR1000KPFAL ZR1000LPFNL |
Verify Stop Sale eligibility using VIP in K-Dealer. Vehicles outside this range are not affected by this Stop Sale Notice.
Subject:
Kawasaki is issuing a stop sale notice for model year 2015~2023 Z H2, Z H2 SE, Ninja H2, Ninja H2 R, Ninja H2 Carbon, Ninja H2 SX, Ninja H2 SX SE & Ninja H2 SX SE+ models.
On eligible units, the plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts. Continuous use in this condition can result in loss of engine power during use.
What Dealers Must Do:
- DISCONTINUE SALES OF 2015~2023 Z H2, Z H2 SE, NINJA H2, NINJA H2 R, NINJA H2 CARBON, NINJA H2 SX, NINJA H2 SX SE & NINJA H2 SX SE+ MODELS
- CONTINUE PROCESSING AND SENDING PRODUCT REGISTRATION PAPERWORK FOR RECENT 2015~2023 Z H2, Z H2 SE, NINJA H2, NINJA H2 R, NINJA H2 CARBON,
NINJA H2 SX, NINJA H2 SX SE & NINJA H2 SX SE+ PURCHASERS
Kawasaki expects to issue repair information to dealers in mid-December of 2022. Owners of eligible units will be notified to contact an authorized Kawasaki
motorcycle dealership to schedule an appointment to complete the repairs.
We apologize for any inconvenience experienced and are working toward a resolution of this matter as quickly as possible.
KAWASAKI MOTORS CORP., U.S.A.
MC 22-08
December 20, 2022
RECALL
Eligible Units
Yr | Model Name | Model Code |
2015 | NINJA H2
NINJA H2 R* | ZX1000NFFL ZX1000PFF* |
2016 | NINJA H2
NINJA H2 R* | ZX1000NGFL ZX1000PGF* |
2017 | NINJA H2
NINJA H2 CARBON NINJA H2 R* | ZX1000XHFL
ZX1000XHFAL ZX1000YHF* |
2018 | NINJA H2
NINJA H2 CARBON NINJA H2 R* NINJA H2 SX NINJA H2 SX SE | ZX1000XJFL
ZX1000XJFAL ZX1000YJF* ZX1002AJF, ZX1002AJFL ZX1002BJF, ZX1002BJFL |
2019 | NINJA H2
NINJA H2 CARBON NINJA H2 SX SE+ | ZX1002JKFL
ZX1002JKFAL ZX1002DKF, ZX1002DKFL |
2020 | NINJA H2
NINJA H2 CARBON NINJA H2 R* NINJA H2 SX SE+ Z H2 | ZX1002JLFL
ZX1002JLFAL ZX1000YLF* ZX1002DLF, ZX1002DLFL ZR1000KLF , ZR1000KLFB, ZR1000KLFL |
2021 | NINJA H2
NINJA H2 CARBON NINJA H2 R* NINJA H2 SX SE+ Z H2 Z H2 SE | ZX1002JMFNL
ZX1002JMANL ZX1000YMFNN* ZX1002DMFNL ZR1000KMFNL ZR1000LMFNL |
2022 | NINJA H2
NINJA H2 CARBON NINJA H2 R* NINJA H2 SX SE Z H2 Z H2 SE | ZX1002JNFNL
ZX1002JNANL ZX1000YNFNN* ZX1002RNFNL ZR1000KNFAL ZR1000LNFNL |
2023 | Z H2
Z H2 SE | ZR1000KPFAL ZR1000LPFNL |
*NINJA H2 R models covered under U.S. Consumer Product Safety Comission (CPSC) recall.
Subject
The plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts, which can result in an engine stall while riding. An engine stall while riding can increase the risk of a crash or injury. Our records indicate that you have purchased one of these units.
Kawasaki Action
Initiate Campaign:
Kawasaki has initiated a Recall campaign to repair all eligible units. The repair consists of replacing the camshaft chain tensioner.
Notify Registered Owners:
Kawasaki is sending a Recall letter to all registered owners of eligible units. A copy of the letter is printed on pages 5 and 6 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 Dealerโs 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.
Parts Information
Repair Kit Part Number:
Kit 99999-0851 must be installed on all eligible units.
Order parts to complete the recall through K-Dealer as outlined in Service Bulletin SP15-03.
Kit, Chain Tensioner, MC22-08
P/N 99999-0851
Ref.# | Contents | Qty |
1 | Tensioner | 1 |
2 | Gasket, Tensioner | 1 |
Repair Procedure
Refer to the applicable service manual for detailed information related to parts removal and installation.
NOTICE
This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.
When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in โCamshaft Chain Tensioner Installation.โ
Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves.
- Remove and retain camshaft chain tensioner mounting bolts [A].
- Remove and discard camshaft chain tensioner [B].
- Verify that stopper [A] is in groove [B] of push rod [C] before installing the tensioner.
IMPORTANT NOTE:
- Be careful not to fit the snap ring [D] into the groove [B] (see images below).
- Replace the gasket [A] with the new one from the repair kit.
- Install the tensioner so that the plug [B] faces upward.
- Tighten the camshaft chain tensioner mounting bolts to 89 inยทlb (1.0 kgfยทm, 10 Nยทm).
IMPORTANT NOTE:
- When installing the tensioner, if the bolts donโt engage the cylinder head, the cam timing may be off. Remove the tensioner and check the cam timing then repeat the cam chain tensioner installation.
Extend Tensioner Pushrod
- Press the starter switch quickly enough to turn the engine over but not long enough to start the engine. This will extend the tensioner pushrod against the camshaft chain.
Repair Verification
The new camshaft chain tensioner stamped with identification number 0120 will serve as repair verification.
NOTE:
- 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.
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision:
- November 2020: Kawasaki
Motors, Ltd. (KML) received a report of abnormal engine noise on a vehicle from its Japanese distributor (KMJ). Upon inspection of the vehicle, KML discovered that the camshaft chain tensioner was locked.
- November 2020: KML asked the supplier of the camshaft chain tensioner to inspect the failed part and report back. The supplier found no abnormalities and reported that there may have been a maintenance issue on the failed unit. The supplier reported to KML that it did not expect further issues with the part.
- March โ June 2021: KML received two additional reports of abnormal engine noise from KMJ, but none from other markets.
- ย September 2021: KML received a report that a vehicle lost power from KMJ. No accident or injuries were reported.
- September 2021: KML Quality Assurance department shared these reports with KML Research & Development department and the supplier, then re-opened its investigation into this issue.
- November 2021: As a result of the in-house investigation KML discovered that certain components of the camshaft chain tensioner varied dimensionally between units, though each was within the tolerance specified by KML for the component. However, KML did not know whether these variances between units were creating the problem.
- February 2022 – September 2022: KML and the supplier continued to test the camshaft chain tensioner to replicate a lock up, first by manually compressing the tensioner, and then during engine operation. KML could not successfully replicate a lock up of the camshaft chain tensioner during engine operation.
- October 2022: After an additional report of lost engine power from KMJ, KML began to look for a solution to this issue, though it still had not determined for certain that the variances between parts were the cause of the issue.
- November 2022: KML decided to use a cam chain tensioner from a different model, which does not have this issue, on these models to eliminate this issue.
- December 2, 2022: KML decided to initiate a recall campaign on these models to ensure that this issue does not occur on vehicles already in the field.
21 Affected Products
Vehicles
MAKE | MODEL | YEAR |
KAWASAKI![]() | ZR1000K | 2020-2023 |
KAWASAKI![]() | ZR1000L | 2021-2022 |
KAWASAKI![]() | ZR1002L | 2023 |
KAWASAKI![]() | ZX1000 | 2015-2018 |
KAWASAKI![]() | ZX1002A | 2018 |
KAWASAKI![]() | ZX1002B | 2018 |
KAWASAKI![]() | ZX1002D | 2019-2021 |
KAWASAKI![]() | ZX1002J | 2019-2022 |
KAWASAKI![]() | ZX1002R | 2022 |
14 Associated Documents
Recall 573 Report – December 14, 2022
RCLRPT-22V912-5524.PDF 214.03KB
Chronology Report
RMISC-22V912-3014.pdf 74.363KB
Attachment A- Model Information
RMISC-22V912-2425.pdf 81.279KB
Manufacturer Notices(to Dealers,etc)
Defect Notice 573 Report
RCLRPT-22V912-2934.PDF 212.795KB
Recall Acknowledgement
RCAK-22V912-8924.pdf 645.594KB
Recall 573 Report – December 15, 2022
RCLRPT-22V912-5523.PDF 214.049KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V912-7757.pdf 129.814KB
Recall 573 Report – December 27, 2022
RCLRPT-22V912-5643.PDF 214.068KB
Remedy Instructions and TSB
RCRIT-22V912-4524.pdf 623.067KB
Recall Quarterly Report #1, 2022-4
RCLQRT-22V912-3991.PDF 211.123KB
Recall Quarterly Report #2, 2023-1
RCLQRT-22V912-1091.PDF 211.223KB
Recall Quarterly Report #3, 2023-2
RCLQRT-22V912-8858.PDF 211.312KB
Recall Quarterly Report – 10/02/2023
RCLQRT-22V912-1420.PDF 211.558KB
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SEOCONTENT-START
OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-912 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Kawasaki Motors Corp., U.S.A. Submission Date : DEC 14, 2022 NHTSA Recall No. : 22V-912 Manufacturer Recall No. : MC22-08 Manufacturer Information : Manufacturer Name : Kawasaki
Motors Corp., U.S.A. Address : PO Box 25252 Santa Ana CA 92799-5252 Company phone : 949-770-0400 Population : Number of potentially involved : 3,172 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2015-2023 Kawasaki
Motors, Ltd. ZX1000N/X, ZX1002J, ZX1002A/B/D/R, ZR1000K/ L Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The affected vehicles containing the problem are certain 2015-2023 ZX1000N/X, ZX1002J (Kawasaki
/Ninja H2/H2 Carbon/830), ZX1002A/B/D/R (Kawasaki
/Ninja H2 SX/SX SE/1,166), ZR1000K/L (Kawasaki
/Z H2/H2 SE/1,176) models. The recall population was determined by the beginning and ending production dates for the models affected. Production Dates : DEC 01, 2014 – SEP 27, 2022 VIN Range 1 : Begin : JKAZXCN10FA000065 End : JKBZXVJ17NA004304 Not sequential VIN Range 2 : Begin : JKBZXVB10JA000006 End : JKBZXVD17MA005141 Not sequential VIN Range 3 : Begin : JKAZRCL11MA000005 End : JKAZRCK16PA015234 Not sequential Description of Defect : Description of the Defect : The plunger in the camshaft-chain tensioner can lock up during usage due to deterioration of internal parts. Continuous use in this condition can result in loss of engine power during use. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk that the engine could stop during operation due to the camshaft timing deviation. Description of the Cause : Deterioration of internal parts in the tensioner during usage. Identification of Any Warning that can Occur : An abnormal noise will be generated around the right side of the engine. Part 573 Safety Recall Report 22V-912 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Involved Components : Component Name 1 : TENSIONER-ASSY Component Description : Camshaft-chain tensioner Component Part Number : 12048-0119 Supplier Identification : Component Manufacturer Name : Kawasaki
Motors Ltd. Address : 1-1, Kawasaki
-cho Akashi Foreign States 673-8666 Country : Japan Chronology : NR Description of Remedy : Description of Remedy Program : All eligible units require the replacement of the tensioner (12048-0120) and the gasket. The plan of reimbursement will be described on the owner’s letter as follows: 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 How Remedy Component Differs from Recalled Component : The difference can be identified by the stamped number on the tensioner, that can be seen easily from outside. Identify How/When Recall Condition was Corrected in Production : From November 2022, the common tensioner has been applied to the assembly line for the commonization. Recall Schedule : Part 573 Safety Recall Report 22V-912 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Recall Schedule : KMC will distribute both electronic and paper copies of a Recall Service bulletin to all Kawasaki
motorcycle dealers. KMC will mail the owner notification letter via U.S.P.S. enclosed in an envelope with the statement โImportant Recall Safety Informationโ printed on the outside of the envelope. Planned Dealer Notification Date : DEC 19, 2022 – DEC 19, 2022 Planned Owner Notification Date : DEC 21, 2022 – DEC 21, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-912 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Kawasaki Motors Corp., U.S.A. Submission Date : DEC 09, 2022 NHTSA Recall No. : 22V-912 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Kawasaki
Motors Corp., U.S.A. Address : PO Box 25252 Santa Ana CA 92799-5252 Company phone : 949-770-0400 Population : Number of potentially involved : 3,172 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2015-2023 Kawasaki
Motors, Ltd. ZX1000N/X, ZX1002J, ZX1002A/B/D/R, ZR1000K/ L Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The affected vehicles containing the problem are certain 2015-2023 ZX1000N/X, ZX1002J (Kawasaki
/Ninja H2/H2 Carbon/830), ZX1002A/B/D/R (Kawasaki
/Ninja H2 SX/SX SE/1,166), ZR1000K/L (Kawasaki
/Z H2/H2 SE/1,176) models. The recall population was determined by the beginning and ending production dates for the models affected. Production Dates : DEC 01, 2014 – SEP 27, 2022 VIN Range 1 : Begin : JKAZXCN10FA000065 End : JKBZXVJ17NA004304 Not sequential VIN Range 2 : Begin : JKBZXVB10JA000006 End : JKBZXVD17MA005141 Not sequential VIN Range 3 : Begin : JKAZRCL11MA000005 End : JKAZRCK16PA015234 Not sequential Description of Defect : Description of the Defect : The plunger in the camshaft-chain tensioner can lock up during usage due to deterioration of internal parts. Continuous use in this condition can result in loss of engine power during use. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk that the engine could stop during operation due to the camshaft timing deviation. Description of the Cause : Deterioration of internal parts in the tensioner during usage. Identification of Any Warning that can Occur : An abnormal noise will be generated around the right side of the engine. Part 573 Safety Recall Report 22V-912 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : Kawasaki Motors Ltd. Address : 1-1, Kawasaki-cho Akashi Foreign States 673-8666 Country : Japan Chronology : NR Description of Remedy : Description of Remedy Program : NR How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : NR Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-912 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Kawasaki Motors Corp., U.S.A. Submission Date : DEC 15, 2022 NHTSA Recall No. : 22V-912 Manufacturer Recall No. : MC22-08 Manufacturer Information : Manufacturer Name : Kawasaki Motors Corp., U.S.A. Address : PO Box 25252 Santa Ana CA 92799-5252 Company phone : 949-770-0400 Population : Number of potentially involved : 3,172 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2015-2023 Kawasaki Motors, Ltd. ZX1000N/X, ZX1002J, ZX1002A/B/D/R, ZR1000K/ L Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The affected vehicles containing the problem are certain 2015-2023 ZX1000N/X, ZX1002J (Kawasaki/Ninja H2/H2 Carbon/830), ZX1002A/B/D/R (Kawasaki/Ninja H2 SX/SX SE/1,166), ZR1000K/L (Kawasaki/Z H2/H2 SE/1,176) models. The recall population was determined by the beginning and ending production dates for the models affected. Production Dates : DEC 01, 2014 – SEP 27, 2022 VIN Range 1 : Begin : JKAZXCN10FA000065 End : JKBZXVJ17NA004304 Not sequential VIN Range 2 : Begin : JKBZXVB10JA000006 End : JKBZXVD17MA005141 Not sequential VIN Range 3 : Begin : JKAZRCL11MA000005 End : JKAZRCK16PA015234 Not sequential Description of Defect : Description of the Defect : The plunger in the camshaft-chain tensioner can lock up during usage due to deterioration of internal parts. Continuous use in this condition can result in loss of engine power during use. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk that the engine could stop during operation due to the camshaft timing deviation, increasing the risk of crash. Description of the Cause : Deterioration of internal parts in the tensioner during usage. Identification of Any Warning that can Occur : An abnormal noise will be generated around the right side of the engine. Part 573 Safety Recall Report 22V-912 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Involved Components : Component Name 1 : TENSIONER-ASSY Component Description : Camshaft-chain tensioner Component Part Number : 12048-0119 Supplier Identification : Component Manufacturer Name : Kawasaki Motors Ltd. Address : 1-1, Kawasaki-cho Akashi Foreign States 673-8666 Country : Japan Chronology : NR Description of Remedy : Description of Remedy Program : All eligible units require the replacement of the tensioner (12048-0120) and the gasket. The plan of reimbursement will be described on the owner’s letter as follows: 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 How Remedy Component Differs from Recalled Component : The difference can be identified by the stamped number on the tensioner, that can be seen easily from outside. Identify How/When Recall Condition was Corrected in Production : From November 2022, the common tensioner has been applied to the assembly line for the commonization. Recall Schedule : Part 573 Safety Recall Report 22V-912 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Recall Schedule : KMC will distribute both electronic and paper copies of a Recall Service bulletin to all Kawasaki motorcycle dealers. KMC will mail the owner notification letter via U.S.P.S. enclosed in an envelope with the statement โImportant Recall Safety Informationโ printed on the outside of the envelope. Planned Dealer Notification Date : DEC 19, 2022 – DEC 19, 2022 Planned Owner Notification Date : DEC 21, 2022 – DEC 21, 2022 * NR – Not Reported
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ยฉ2022, Kawasaki Motors Corp., U.S.A. SERVICE MC 22-08 December 20, 2022 Page 1 of 6 TITLE: 2015~2023 Z H2, Z H2 SE, NINJA H2โข, NINJA H2โขR, NINJA H2โขSX, NINJA H2โขCARBON, NINJA H2โขSX SE & NINJA H2โขSX SE+ CAMSHAFT CHAIN TENSIONER REPLACEMENT Kawasaki Action Initiate Campaign: Kawasaki has initiated a Recall campaign to repair all eligible units. The repair consists of replacing the camshaft chain tensioner. Notify Registered Owners: Kawasaki is sending a Recall letter to all registered owners of eligible units. A copy of the letter is printed on pages 5 and 6 of this bulletin. Eligibility Eligible Units Yr Model Name Model Code 2015 NINJA H2 NINJA H2 R* ZX1000NFFL ZX1000PFF* 2016 NINJA H2 NINJA H2 R* ZX1000NGFL ZX1000PGF* 2017 NINJA H2 NINJA H2 CARBON NINJA H2 R* ZX1000XHFL ZX1000XHFAL ZX1000YHF* 2018 NINJA H2 NINJA H2 CARBON NINJA H2 R* NINJA H2 SX NINJA H2 SX SE ZX1000XJFL ZX1000XJFAL ZX1000YJF* ZX1002AJF, ZX1002AJFL ZX1002BJF, ZX1002BJFL 2019 NINJA H2 NINJA H2 CARBON NINJA H2 SX SE+ ZX1002JKFL ZX1002JKFAL ZX1002DKF, ZX1002DKFL 2020 NINJA H2 NINJA H2 CARBON NINJA H2 R* NINJA H2 SX SE+ Z H2 ZX1002JLFL ZX1002JLFAL ZX1000YLF* ZX1002DLF, ZX1002DLFL ZR1000KLF , ZR1000KLFB, ZR1000KLFL 2021 NINJA H2 NINJA H2 CARBON NINJA H2 R* NINJA H2 SX SE+ Z H2 Z H2 SE ZX1002JMFNL ZX1002JMANL ZX1000YMFNN* ZX1002DMFNL ZR1000KMFNL ZR1000LMFNL 2022 NINJA H2 NINJA H2 CARBON NINJA H2 R* NINJA H2 SX SE Z H2 Z H2 SE ZX1002JNFNL ZX1002JNANL ZX1000YNFNN* ZX1002RNFNL ZR1000KNFAL ZR1000LNFNL 2023 Z H2 Z H2 SE ZR1000KPFAL ZR1000LPFNL *NINJA H2 R models covered under U.S. Consumer Product Safety Comission (CPSC) recall. 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 The plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts, which can result in an engine stall while riding. An engine stall while riding can increase the risk of a crash or injury. Our records indicate that you have purchased one of these 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 Dealerโs 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 Itโs 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 Page 2 Parts Information Repair Kit Part Number: Kit 99999-0851 must be installed on all eligible units. Order parts to complete the recall through K-Dealer as outlined in Service Bulletin SP15-03. Parts Availability: To ensure parts availability across the dealer network, Kawasaki initially requests that parts are ordered based on immediate demand: โข For retailed units, order parts as customers schedule repairs or for repairs expected to take place within the next two weeks. โข 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. NOTE: o Use VIP in K-Dealer to identify affected units in your dealership inventory to order repair kits for unsold units. Dealer Action (continued) 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. Kit, Chain Tensioner, MC22-08 P/N 99999-0851 Ref.# Contents Qty 1 Tensioner 1 2 Gasket, Tensioner 1 1 2 Page 3 Repair Procedure Refer to the applicable service manual for detailed information related to parts removal and installation. โข Remove and retain camshaft chain tensioner mounting bolts [A]. โข Remove and discard camshaft chain tensioner [B]. โข Verify that stopper [A] is in groove [B] of push rod [C] before installing the tensioner. NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below. When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in โCamshaft Chain Tensioner Installation.โ Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. B C A B D A IMPORTANT NOTE: o Be careful not to fit the snap ring [D] into the groove [B] (see images below). A CORRECT INCORRECT STOPPER STOPPER GROOVE SNAP RING SNAP RING GROOVE Page 4 Repair Procedure – (continued) โข Replace the gasket [A] with the new one from the repair kit. โข Install the tensioner so that the plug [B] faces upward. โข Tighten the camshaft chain tensioner mounting bolts to 89 inยทlb (1.0 kgfยทm, 10 Nยทm). Extend Tensioner Pushrod โข Press the starter switch quickly enough to turn the engine over but not long enough to start the engine. This will extend the tensioner pushrod against the camshaft chain. B A IMPORTANT NOTE: o When installing the tensioner, if the bolts donโt engage the cylinder head, the cam timing may be off. Remove the tensioner and check the cam timing then repeat the cam chain tensioner installation. Warranty Information This is a Recall. 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. 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. Replace Tensioner Job Code 22575 Flat Rate Time 0.2 hrs Claim Type 3 Part Number 99999-0851 Description Kit, Chain Tensioner, MC22-08 Quantity 1 Repair Verification The new camshaft chain tensioner stamped with identification number 0120 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. OLD PART NO STAMP NEW PART 0120 STAMP Page 5 IMPORTANT SAFETY RECALL NHTSA RECALL NO. 22V-912 2015~2023 Z H2, Z H2 SE, NINJA H2โข, NINJA H2โขSX, NINJA H2โขCARBON, NINJA H2โขSX SE & NINJA H2โขSX SE+ CAMSHAFT CHAIN TENSIONER REPLACEMENT 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 2015~2022 NINJA H2, 2017~2022 NINJA H2 CARBON, 2018 NINJA H2 SX, 2018 & 2022 NINJA H2 SX SE, 2019~2021 NINJA H2 SX SE+, 2020~2023 Z H2 and 2021~2023 Z H2 SE model vehicles. The reason for this notice: The plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts, which can result in an engine stall while riding. An engine stall while riding can increase the risk of a crash or injury. 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 camshaft chain tensioner free of charge. The actual repair will take up to 15 minutes but 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 repaired. 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 โLOCATE DEALERโ link. 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 VIN 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 http://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 โOWNER CENTER => KAWASAKI SUPPORT => UPDATE OWNER INFOโ 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. Page 6 IMPORTANT SAFETY RECALL 2015~2018 & 2020~2022 NINJA H2โขR CAMSHAFT CHAIN TENSIONER REPLACEMENT Dear Kawasaki Motorcycle Owner: This notice is sent to you in accordance with the requirements of the Consumer Product Safety Act. The reason for this notice: This letter is sent to notify you that Kawasaki, in cooperation with the U.S. Consumer Product Safety Commission, has initiated a voluntary safety Recall Campaign to replace the camshaft chain tensioner on certain 2015~2018 & 2020~2022 NINJA H2 R models. Our records indicate that you have purchased one of these units. The plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts, which can result in an engine stall while riding. An engine stall while riding can increase the risk of a crash or injury. 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 camshaft chain tensioner free of charge. The actual repair will take up to 15 minutes but 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 repaired. 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 โLOCATE DEALERโ link. 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 VIN ready when calling. 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 โOWNER CENTER => KAWASAKI SUPPORT => UPDATE OWNER INFOโ 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. 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.
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Continued on next page Kawasaki Motors Corp., U.S.A. P.O. Box 25252, Santa Ana, California 92799-5252 IMPORTANT SAFETY RECALL NHTSA RECALL NO. 22V-912 2015~2023 Z H2, Z H2 SE, NINJA H2โข, NINJA H2โขSX, NINJA H2โขCARBON, NINJA H2โขSX SE & NINJA H2โขSX SE+ CAMSHAFT CHAIN TENSIONER REPLACEMENT THIS NOTICE APPLIES TO YOUR VEHICLE VIN:JKBXXXXXXXXXXXXXX OWNER NAME MODEL CODE MC22-08 ADDRESS ENGINE: XXXXXXXXXXXXX CITY, STATE, ZIP FRAME: XXXXXX DATE: DEC 2022 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 2015~2022 NINJA H2, 2017~2022 NINJA H2 CARBON, 2018 NINJA H2 SX, 2018 & 2022 NINJA H2 SX SE, 2019~2021 NINJA H2 SX SE+, 2020~2023 Z H2 and 2021~2023 Z H2 SE model vehicles. The reason for this notice: The plunger in the camshaft chain tensioner can lock up during usage due to deterioration of internal parts, which can result in an engine stall while riding. An engine stall while riding can increase the risk of a crash or injury. 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 camshaft chain tensioner free of charge. The actual repair will take up to 15 minutes but 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 repaired. 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 โLOCATE DEALERโ link.. 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 VIN 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 http://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 โOWNER CENTER => KAWASAKI SUPPORT => UPDATE OWNER INFOโ 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.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-912 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Kawasaki Motors Corp., U.S.A. Submission Date : DEC 27, 2022 NHTSA Recall No. : 22V-912 Manufacturer Recall No. : MC22-08 Manufacturer Information : Manufacturer Name : Kawasaki Motors Corp., U.S.A. Address : PO Box 25252 Santa Ana CA 92799-5252 Company phone : 949-770-0400 Population : Number of potentially involved : 3,172 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2015-2023 Kawasaki Motors, Ltd. ZX1000N/X, ZX1002J, ZX1002A/B/D/R, ZR1000K/ L Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The affected vehicles containing the problem are certain 2015-2023 ZX1000N/X, ZX1002J (Kawasaki/Ninja H2/H2 Carbon/830), ZX1002A/B/D/R (Kawasaki/Ninja H2 SX/SX SE/1,166), ZR1000K/L (Kawasaki/Z H2/H2 SE/1,176) models. The recall population was determined by the beginning and ending production dates for the models affected. Production Dates : DEC 01, 2014 – SEP 27, 2022 VIN Range 1 : Begin : JKAZXCN10FA000065 End : JKBZXVJ17NA004304 Not sequential VIN Range 2 : Begin : JKBZXVB10JA000006 End : JKBZXVD17MA005141 Not sequential VIN Range 3 : Begin : JKAZRCL11MA000005 End : JKAZRCK16PA015234 Not sequential Description of Defect : Description of the Defect : The plunger in the camshaft-chain tensioner can lock up during usage due to deterioration of internal parts. Continuous use in this condition can result in loss of engine power during use. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk that the engine could stop during operation due to the camshaft timing deviation, increasing the risk of crash. Description of the Cause : Deterioration of internal parts in the tensioner during usage. Identification of Any Warning that can Occur : An abnormal noise will be generated around the right side of the engine. Part 573 Safety Recall Report 22V-912 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Involved Components : Component Name 1 : TENSIONER-ASSY Component Description : Camshaft-chain tensioner Component Part Number : 12048-0119 Supplier Identification : Component Manufacturer Name : Kawasaki Motors Ltd. Address : 1-1, Kawasaki-cho Akashi Foreign States 673-8666 Country : Japan Chronology : Chronology is attached as a miscellaneous document. Description of Remedy : Description of Remedy Program : All eligible units require the replacement of the tensioner (12048-0120) and the gasket. The plan of reimbursement will be described on the owner’s letter as follows: 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 How Remedy Component Differs from Recalled Component : The difference can be identified by the stamped number on the tensioner, that can be seen easily from outside. Identify How/When Recall Condition was Corrected in Production : From November 2022, the common tensioner has been applied to the assembly line for the commonization. Recall Schedule : Part 573 Safety Recall Report 22V-912 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Recall Schedule : KMC will distribute both electronic and paper copies of a Recall Service bulletin to all Kawasaki motorcycle dealers. KMC will mail the owner notification letter via U.S.P.S. enclosed in an envelope with the statement โImportant Recall Safety Informationโ printed on the outside of the envelope. Planned Dealer Notification Date : DEC 19, 2022 – DEC 19, 2022 Planned Owner Notification Date : DEC 21, 2022 – DEC 21, 2022 * NR – Not Reported
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