MC27-04 – Damaged Spark Plugs May Cause Engine Stall – 2023-2024 Kawasaki ZX400S & ZX400P (2023 Ninja ZX-4RR KRT Edition, 2024 Ninja ZX-4R, & 4RR) Motorcycles

SEOCONTENT-START

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-221
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Kawasaki Motors Corp., U.S.A. MAR 21, 2024 NHTSA Recall No. : 24V-221 Manufacturer Recall No. : MC27-04 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 : 1,579 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2023-2024 Kawasaki Motors, Ltd. ZX400S / ZX400P Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : The affected vehicles are certain 2023 and 2024 ZX400S / P models
( Kawasaki/2023/Ninja® ZX-4RR KRT Edition/999 – Kawasaki/2024/Ninja®
ZX™-4R ABS/140 – Kawasaki/2024/ Ninja® ZX™-4RR 40th Anniversary Edition ABS/ 120 Kawasaki/2024/Ninja® ZX™-4RR ABS/180 – Kawasaki/2024/Ninja® ZX™-4RR KRT Edition ABS/140) models. The recall population was determined by the beginning manufacturing date until November 14th, 2023
Production Dates : OCT 04, 2023 – NOV 14, 2023
VIN Range 1 : Begin : ML5ZXCS11PDA00082 End : ML5ZXCS10PDA01482 Not sequential VIN Range 2 : Begin : ML5ZXCP15RDA09931 End : ML5ZXCP16RDA14989 Not sequential VIN Range 3 : Begin : ML5ZXCS10RDA09911 End : ML5ZXCS10RDA14669 Not sequential VIN Range 4 : Begin : ML5ZXCS11RDA09951 End : ML5ZXCS13RDA13869 Not sequential VIN Range 5 : Begin : ML5ZXCS17RDA09971 End : ML5ZXCS1XRDA14209 Not sequential Description of Defect :
Description of the Defect : On certain eligible units, the spark plugs may have been damaged during the vehicle manufacturing process. It may result in unstable idle, hesitation and in the worst case, engine stalling.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : There is a risk that the engine may stall due to the damaged spark plugs. Description of the Cause : Error during installation of the spark plugs Part 573 Safety Recall Report 24V-221 Page 2 Identification of Any Warning
that can Occur : Unstable idle and hesitation Involved Components : Component Name 1 : PLUG-SPARK,LMAR9G(NGK)
Component Description : Spark plug Component Part Number : 92070-0716 Supplier Identification : Component Manufacturer
Name : Kawasaki Motors Ltd.
Address : 1-1, Kawasaki-cho
Akashi, Hyogo Foreign States 673-8666 Country : Japan Chronology :
・December 2023: Kawasaki Motors, Ltd (KML) received a report from its Chinese distributor subsidiary (KMSH) of several instances of rough idling. KMSH suspected that the cause was malfunctioning spark plugs.
KML Quality Assurance Division started an investigation of the cause.
・January 2024: Kawasaki’s spark plug supplier reported to KML that spark plugs were being cracked by an external force somehow.
・February 2024: After investigating the manufacturing process for this model, KML determined that the spark plug tightening tool was tilted during installation, applying force laterally to the spark plugs and creating the
opportunity for the spark plugs to be cracked during manufacture.
・February 2024: KML reproduced this phenomenon in testing using cracked spark plugs, which revealed that not only rough idling, but stalling could also occur.
・March 21, 2024：KML decided to initiate a recall campaign. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-221
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : All eligible units require to replace all four spark plugs. The plan of
reimbursement has been 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 :
Identify How/When Recall Condition was Corrected in Production : Add a white mark on near the engine number. From November 2023, the tool for tighten spark plug process was replaced and the spark plug tightening tool is not able to tilt when installing into the cylinder head with the new tool. Recall Schedule :
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 “Important Recall Safety Information” printed on the outside of the envelope.
Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-221
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Kawasaki Motors Corp., U.S.A. MAR 22, 2024 NHTSA Recall No. : 24V-221 Manufacturer Recall No. : MC27-04 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 : 1,579 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2023-2024 Kawasaki Motors, Ltd. ZX400S / ZX400P Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : The affected vehicles are certain 2023 and 2024 ZX400S / P models
( Kawasaki/2023/Ninja® ZX-4RR KRT Edition/999 – Kawasaki/2024/Ninja®
ZX™-4R ABS/140 – Kawasaki/2024/ Ninja® ZX™-4RR 40th Anniversary Edition ABS/ 120 Kawasaki/2024/Ninja® ZX™-4RR ABS/180 – Kawasaki/2024/Ninja® ZX™-4RR KRT Edition ABS/140) models. The recall population was determined by the beginning manufacturing date until November 14th, 2023
Production Dates : JAN 11, 2023 – NOV 14, 2023
VIN Range 1 : Begin : ML5ZXCS11PDA00082 End : ML5ZXCS10PDA01482 Not sequential VIN Range 2 : Begin : ML5ZXCP15RDA09931 End : ML5ZXCP16RDA14989 Not sequential VIN Range 3 : Begin : ML5ZXCS10RDA09911 End : ML5ZXCS10RDA14669 Not sequential VIN Range 4 : Begin : ML5ZXCS11RDA09951 End : ML5ZXCS13RDA13869 Not sequential VIN Range 5 : Begin : ML5ZXCS17RDA09971 End : ML5ZXCS1XRDA14209 Not sequential Description of Defect :
Description of the Defect : On certain eligible units, the spark plugs may have been damaged during the vehicle manufacturing process. It may result in unstable idle, hesitation and in the worst case, engine stalling.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : There is a risk that the engine may stall due to the damaged spark plugs. Description of the Cause : Error during installation of the spark plugs Part 573 Safety Recall Report 24V-221 Page 2 Identification of Any Warning
that can Occur : Unstable idle and hesitation Involved Components : Component Name 1 : PLUG-SPARK,LMAR9G(NGK)
Component Description : Spark plug Component Part Number : 92070-0716 Supplier Identification : Component Manufacturer
Name : Kawasaki Motors Ltd.
Address : 1-1, Kawasaki-cho
Akashi, Hyogo Foreign States 673-8666 Country : Japan Chronology :
・December 2023: Kawasaki Motors, Ltd (KML) received a report from its Chinese distributor subsidiary (KMSH) of several instances of rough idling. KMSH suspected that the cause was malfunctioning spark plugs.
KML Quality Assurance Division started an investigation of the cause.
・January 2024: Kawasaki’s spark plug supplier reported to KML that spark plugs were being cracked by an external force somehow.
・February 2024: After investigating the manufacturing process for this model, KML determined that the spark plug tightening tool was tilted during installation, applying force laterally to the spark plugs and creating the
opportunity for the spark plugs to be cracked during manufacture.
・February 2024: KML reproduced this phenomenon in testing using cracked spark plugs, which revealed that not only rough idling, but stalling could also occur.
・March 21, 2024：KML decided to initiate a recall campaign. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-221
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : All eligible units require to replace all four spark plugs. The plan of
reimbursement has been 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 :
Identify How/When Recall Condition was Corrected in Production : Add a white mark on near the engine number. From November 2023, the tool for tighten spark plug process was replaced and the spark plug tightening tool is not able to tilt when installing into the cylinder head with the new tool. Recall Schedule :
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 “Important Recall Safety Information” printed on the outside of the envelope.
Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR
* NR – Not Reported

**************************************************************************************************************

©2024, Kawasaki Motors Corp., U.S.A.
SERVICE MC 24-07
March 29, 2024
Page 1 of 21
TITLE: 2023 NINJA® ZX™-4RR & 2024 NINJA® ZX™-4R & 4RR
Spark Plug Replacement
Kawasaki Action
Initiate Campaign:
Kawasaki has initiated a Recall campaign to replace
the spark plugs.
Notify Registered Owners:
Kawasaki is sending a Recall letter to all registered
owners of eligible units. A copy of the letter is printed
on page 21 of this bulletin.
Eligibility
Eligible Units
Year Model Name Model Code
2023 NINJA ZX-4RR KRT EDITION ZX400SPFNL
2024
NINJA ZX-4R ABS
NINJA ZX-4RR 40TH
ANNIVERSARY EDITION ABS
NINJA ZX-4RR ABS
NINJA ZX-4RR KRT EDITION ABS
ZX400PRFNL
ZX400SRFAL
ZX400SRFBL
ZX400SRFNL
Verify individual vehicle eligibility using VIP in
K-Dealer before starting the repair.
Please check VIP (Vehicle Information Portal) in
K-Dealer for other possible repair campaigns for
eligible units.
Subject
On eligible units, the spark plugs may have
been damaged during the vehicle manufacturing
process. It may result in unstable idle, hesitation,
and engine stalling.
Dealer Action
Repair Eligible Units:
Repair all eligible units including sold units in the field
and unsold units in your dealership inventory prior
to delivery to the retail purchaser. It is the obligation
of authorized Kawasaki retail Dealers to repair
eligible units in Dealer’s possession prior to retail
sale. Failure to comply with this obligation to repair
all units eligible for Recall or FDM campaigns by the
Dealer constitutes a breach of the Dealer Sales and
Service Agreement. Refer to Service Policies bulletin
SP 08-01. Refer to the Repair Procedure section of
this bulletin for details.
IMPORTANT NOTE:
It’s 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.
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.
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:
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:
•
For retailed units, order parts as customers schedule repairs or for repairs expected to take place within the next two weeks.
•
For unsold units, use VIP in K-Dealer to identify the number of affected units in your dealership inventory. Order repair parts only for units that will be repaired for retail sale within the next two weeks.
Kit, Plug-Spark
MC24-06P/N 99999-0939
Contents
Qty
Plug-Spark
4
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.
Workflow Summary
Disassembly
1.
Remove Seats (15-16)
2.
Disconnect Negative Battery Terminal (16-20)
3.
Remove Sliders (if equipped) (15-42)
4.
Remove Lower Inner Fairing (15-18)
5.
Remove Lower Fairing (15-18)
6.
Remove Side Covers (15-27)
7.
Remove Fuel Tank (3-35)
8.
Remove Air Cleaner Housing (3-31)
9.
Remove Stick Coils (16-34)
10.
Remove and Replace Spark Plugs (2-62)
Assembly
1.
Install stick coils (16-34)
2.
Install Air Cleaner Housing (3-33)
3.
Install Fuel Tank (3-38)
4.
Install Side Covers (15-26)
5.
Install Lower Fairing (15-19)
6.
Install Sliders (if equipped) (15-43)
7.
Connect Negative Battery Terminal (16-20)
8.
Install Seats (15-16)
9.
Apply Repair Verification Mark
Refer to pages indicated in service manual 99832-0244-05 for detailed information related to parts removal and installation.
Page 3
Repair Procedure
Refer to service manual 99832-0244-05 for detailed information related to parts removal and installation.
•
Disconnect the negative (–) cable [C].
•
Stow negative cable away from battery terminal.
•
Turn the ignition switch off.
•
Wait until the engine cools down.
•
Insert the ignition key [A] into the seat lock.
•
Turn the key clockwise, and pull up the front part of rear seat [B].
•
Remove the rear seat forward.
•
Pull up the rear part of front seat [A] while pulling the seat lock cable [B] backward.
•
Remove the front seat backward.
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
NOTICE
Fuel tank removal is required for this repair. Allow the engine to cool down completely before beginning this repair to reduce the risk of fire or explosion.
Page 4
Repair Procedure (continued)
Slider Removal (if equipped)
•
Remove and retain bolts [A] from both sides of the motorcycle.
•
Remove and retain cover [B] from both sides of the motorcycle.
•
Remove and retain bolt and washer [A] from both sides of the motorcycle.
•
Remove and retain slider [B] from both sides of the motorcycle.
Lower Inner Fairing Removal
•
Remove 2 quick rivets [A] from the RH side of the fairing.
•
Remove 2 quick rivets from the LH side of the fairing (not shown).
REMOVE BOTH SIDES
REMOVE BOTH SIDES
REMOVE BOTH SIDES
NOTE:
o
Left side shown. Right side similar.
NOTE:
o
Left side shown. Right side similar.
NOTE:
o
Right side shown. Left side similar. Repeat right side.
•
Remove and retain 6 quick rivets [A].
•
Pull the lower inner fairing [B] backward to clear the tabs [C].
•
Remove lower inner fairing [B]
ABOVE FRONT FENDER
Page 5
Repair Procedure (continued)
•
Remove and retain bolt [A] from LH and RH fairing.
•
Remove and retain quick rivets [A] from the top of the RH and LH fairing.
Lower Fairing Removal
•
Remove and retain 2 quick rivets [A] from bottom center of fairing assembly.
A
A
ABOVE FRONT FENDER
A
BOTTOM CENTER
•
Remove and retain bolt [A] from RH fairing.
•
Remove and retain bolt and collar [B] from RH fairing only.
•
Pull right lower fairing [C] outward to clear projection [D].
RIGHT
SIDE
A
NOTE:
o
Right side shown. Left side similar. Repeat right side.
REMOVE BOTH SIDES
Page 6
Repair Procedure (continued)
•
Pull RH lower fairing [A] outward to clear projections [B].
•
Disconnect front right turn signal light connector [A].
•
Remove LH lower fairing in the same manner as the RH lower fairing described in the previous step.
RIGHT
SIDE
RIGHT
SIDE
LEFT
SIDE
•
Remove and retain bolt [A].
•
Remove and retain bolt and collar [B].
Page 7
Repair Procedure (continued)
•
Remove and retain bolt [A].
•
Remove and retian bolts and washers [B].
•
Remove and retain bolt and collar [C].
•
Remove and retain bolt, collar and damper [A].
•
Remove and retain bolt [B].
•
Pull the side cover [C] outward to clear the projections [D].
NOTE:
o
Left side shown. Right side similar. Repeat right side.
•
Pull the side cover [A] rearward to clear the hook [B].
NOTE:
o
Left side shown. Right side similar. Repeat right side.
NOTE:
o
Left side shown. Right side similar. Repeat right side.
REMOVE BOTH SIDES
REMOVE BOTH SIDES
REMOVE BOTH SIDES
Page 8
Repair Procedure (continued)
•
Draw the fuel out from the fuel tank with a commercially available pump [A].
•
Use a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly.
•
Put the hose through the fill opening [C] into the tank and draw the fuel out.
•
Open the fuel tank cap [A] to lower the pressure in the tank.
•
During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less.
•
Slide clamps [A] down.
•
Disconnect breather hose [B].
•
Disconnect drain hose [C].
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch off. Disconnect the battery (-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
WARNING
Spilled fuel is flammable and can be explosive under certain conditions. The fuel can not be removed completely from the fuel tank. Be careful for remained fuel spillage.
Page 9
Repair Procedure (continued)
•
Open clamp [A].
•
Remove and retain bolts [B].
•
Wipe off any dirt from the surface [A] around the connection using a cloth or a soft brush before disconnecting the fuel hose joint.
•
Be sure to place a piece of cloth around the fuel hose joint to catch spilled fuel.
•
Disconnect fuel pump connector [A].
When removing with flat tip screwdriver:
•
Insert the flat tip screwdriver [A] into slit on the joint lock[B].
•
Turn the screwdriver to disconnect the joint lock.
When removing with fingers:
•
Open and push up [C] the joint lock with your fingers.
NOTICE
Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock, resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion. To prevent fire or explosion from a damaged joint lock, do not pry or excessively widen the joint lock ends when removing the fuel hose. The joint lock has a retaining edge that locks around the housing.
Page 10
•
Pull [A] the fuel hose joint [B] out of the outlet pipe.
•
Close the fuel tank cap.
•
Remove the fuel tank [A] rearward to clear the projections [B] from the dampers [C], and place it on a flat surface.
•
Do not apply pressure or side load to the fuel pipe connected to the fuel pump.
Repair Procedure (continued)
•
Clean the pipe [A].
•
Cover the pipe and the hose joint [B] with plastic bags [C] to keep them clean.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuelmust be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
•
Remove and retain heat insulation rubber plate [A].
•
Remove the ECU [B] with the harness connected from the air cleaner housing.
Page 11
Repair Procedure (continued)
•
Remove and retain air cleaner housing bolt [A].
•
Open clamp [B].
•
Slide clamp [A] down and disconnect breather hose [B].
•
Disconnect intake air temperature sensor connector [C].
•
Slide clamp [A] down and disconnect drain hose [B].
•
Disconnect the air switching valve hose [A].
•
Loosen the air cleaner housing clamp bolt [B] on both sides.
Page 12
•
Loosen the intake duct clamp bolt [A].
•
Remove the air cleaner housing.
•
Remove the spark plugs [A] using a 14 mm spark plug socket.
•
Insert each new spark plug vertically into the spark plug hole with the spark plug installed in the plug wrench, and finger-tighten it first.
•
Disconnect stick coil connectors [A].
•
Remove and retain stick coils [B].
NOTICE
Never drop the stick coils, especially on a hard surface. Such a shock to the stick coils can damage them.
NOTICE
Do not pry the connector part of the coil while removing the coil.
NOTICE
Tightening the spark plug with the socket tilted can break the insulator.
•
Tighten spark plugs to 115 in·lb (1.3 kgf·m,
13 N·m)
Repair Procedure (continued)
•
Install the stick coils [A] with their connectors facing to the specified angles [B] as shown.
NOTE:
o
The specified angels are indicated on the cylinder head cover and the heat insulation rubber plate.
NOTICE
Do not tap the coil heads while installing the coils.
•
After installation, be sure the stick coils are installed securely by pulling them up lightly.
NOTICE
Use a spark plug socket with a rubbler insert to remove and replace the spark plugs.
SPARK PLUG SOCKET ONLY
Page 13
Repair Procedure (continued)
•
Install air cleaner housing.
•
Check the rubber duct [A] is in place on the air cleaner housing [B].
•
Tighten air cleaner housing clamp bolts to
18 in·lb (0.20 kgf·m, 2.0 N·m)
•
Fit the hole of clamp [C] to the projection [D] of rubber duct.
•
Tighten intake duct clamp bolt to 26 in·lb
(0.30 kgf·m, 2.9 N·m).
•
Tighten the air cleaner housing clamp bolt [B] on both sides.
•
Connect the air switching valve hose [A].
•
Tighten the intake duct clamp bolt [A].
•
Connect drain hose [B]
•
Secure clamp [A].
Page 14
Repair Procedure (continued)
•
Install the ECU [B] with the harness connected to the air cleaner housing.
•
Install Heat Insulation Rubber Plate [A].
•
Secure Clamp [B]
•
Install Air Cleaner Housing Bolt [A] and tighten to 71 in·lb (0.82 kgf·m, 8.0 N·m).
•
Connect intake air temperature sensor connector [C].
•
Connect breather hose [B].
•
Slide the clamp [A] up to secure hose [B].
•
Remove the plastic bags [C] from pipe [A] and connector [B].
Page 15
Repair Procedure (continued)
•
Insert the projections [A] of the fuel tank to the dampers [B].
•
Check that the dampers [A], pad [B] and trim [C] are in place on the frame and fuel tank. (refer to images to the right and below)
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuelmust be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
Page 16
•
Tighten the fuel tank bolts [B] following the specified tightening sequence [1 – 4].
•
Secure clamp [A].
Repair Procedure (continued)
•
Connect fuel pump connector [A].
1
2
3
4
•
Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks.
•
Push the joint lock [B] until the hose joint clicks.
•
Push and pull [A] the hose joint [B] back and forth more than two times to make sure it is locked and does not come off.
WARNING
Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is installed correctly on the delivery pipe.
Page 17
Repair Procedure (continued)
•
Push the lower fairing [A] inward to insert the projections [B].
INSERT BOTH SIDES
NOTE:
o
Right side shown. Left side similar. Repeat left side.
•
Push the right lower fairing [C] inward to insert the projection [D].
•
Tighten bolt [A], bolt and collar [B].
RIGHT
SIDE
•
Install drain hose [C].
•
Connect breather hose [B].
•
Secure clamps [A].
•
Connect front right turn signal light connector [A]
RIGHT
SIDE
Page 18
Repair Procedure (continued)
•
Install quick rivets [A] on the right hand side.
•
Install and tighten bolt [A] on the right hand side
A
A
INSTALL BOTH SIDES
INSTALL BOTH SIDES
NOTE:
o
Right side shown. Left side similar. Repeat left side.
NOTE:
o
Right side shown. Left side similar. Repeat left side.
•
Insert the projections [A] of the side cover into the grommets [B].
LEFT
SIDE
•
Install quick rivets [A].
BOTTOM CENTER
Page 19
Repair Procedure (continued)
•
Install slider [B], if equipped and tighten bolt and washer [A].
•
Tighten bolts [A] and install cover [B].
INSTALL BOTH SIDES
INSTALL BOTH SIDES
•
Push the lower inner fairing [B] forward to insert the tabs [C]:
•
Install quick rivet [A]
•
Install quick rivets [A] (Both sides).
ABOVE FRONT FENDER
NOTE:
o
Right side shown. Left side similar. Repeat left side.
INSTALL BOTH SIDES
Page 20
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.
Procedure
Replace Spark Plugs
Job Code
22584
Flat Rate Time
1.0 hrs
Claim Type
3
Part Number
99999-0939
Description
KIT, PLUG-SPARK, MC24-07
Quantity
1
Inspection & Repair Verification
Make a white paint mark [M] to the left of the first digit of the engine number as shown.
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.
M
•
Connect the negative (–) cable [C].
•
lnstall front and rear seats.
•
Test the right front turn signal for operation.
INSTALL BOTH SEATS
Repair Procedure (continued)
Page 21
IMPORTANT SAFETY RECALL
NHTSA RECALL NO. 24V-XXX
2023 NINJA® ZX™-4RR & 2024 NINJA® ZX™-4R & 4RR
SPARK PLUG 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 that relates to vehicle safety exists in certain 2023 Ninja ZX-4RR KRT Edition and 2024 Ninja ZX-4R and 4RR model motorcycles.
What is the reason for this notice?
The spark plugs may have been damaged during the vehicle manufacturing process. It may result in unstable idle, hesitation, and engine stalling. Our records indicate that you have purchased one of these units.
What Kawasaki and your dealer will do:
At no cost to you, Kawasaki has authorized your dealer to replace the spark plugs. The repair will take up to one (1) hour 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 “LOCATE DEALER” link.
If you need help:
If you have questions or concerns that your dealer is not able to resolve, please contact Kawasaki’s Customer Care Department at (866) 802-9381 (toll-free) between 7:00 a.m. and 4:00 p.m. PT Monday through Friday. Please have your Vehicle Identification Number (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 “OWNER CENTER => KAWASAKI SUPPORT => UPDATE OWNER INFO” 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 information, VIN, and 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:
Current owner information, VIN, and copies of repair orders with payment confirmation must be provided. Claims may be denied if proper documentation is not 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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Kawasaki Motors Corp., U.S.A.
P.O. Box 25252, Santa Ana, California 92799-5252
IMPORTANT SAFETY RECALL
NHTSA RECALL NO. 24V-221
2023 NINJA® ZX™-4RR & 2024 NINJA® ZX™-4R & 4RR SPARK PLUG REPLACEMENT
THIS NOTICE APPLIES TO YOUR MOTORCYCLE VIN:JKBXXXXXXXXXXXXXX
OWNER NAME MODEL CODE MC24-07
ADDRESS ENGINE: XXXXXXXXXXXXX
CITY, STATE, ZIP FRAME: XXXXXX
DATE: MAR 2024
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 that relates to vehicle safety exists in certain 2023 Ninja ZX-4RR KRT Edition and 2024 Ninja ZX-4R and 4RR model motorcycles.
What is the reason for this notice?
The spark plugs may have been damaged during the vehicle manufacturing process. It may result in unstable idle, hesitation, and engine stalling. Our records indicate that you have purchased one of these units.
What Kawasaki and your dealer will do:
At no cost to you, Kawasaki has authorized your dealer to replace the spark plugs. The repair will take up to one hour 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 “LOCATE DEALER” link.
If you need help:
If you have questions or concerns that your dealer is not able to resolve, please contact Kawasaki’s Customer Care Department at (866) 802-9381 (toll-free) between 7:00 a.m. and 4:00 p.m. PT Monday through Friday. Please have your Vehicle Identification Number (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 “OWNER CENTER => KAWASAKI SUPPORT => UPDATE OWNER INFO” 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 information, VIN, and 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:
Current owner information, VIN, and copies of repair orders with payment confirmation must be provided. Claims may be denied if proper documentation is not 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 24V-221
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Kawasaki Motors Corp., U.S.A. MAR 27, 2024 NHTSA Recall No. : 24V-221 Manufacturer Recall No. : MC27-04 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 : 1,579 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2023-2024 Kawasaki Motors, Ltd. ZX400S / ZX400P Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : The affected vehicles are certain 2023 and 2024 ZX400S / P models
( Kawasaki/2023/Ninja® ZX-4RR KRT Edition/999 – Kawasaki/2024/Ninja®
ZX™-4R ABS/140 – Kawasaki/2024/ Ninja® ZX™-4RR 40th Anniversary Edition ABS/ 120 Kawasaki/2024/Ninja® ZX™-4RR ABS/180 – Kawasaki/2024/Ninja® ZX™-4RR KRT Edition ABS/140) models. The recall population was determined by the beginning manufacturing date until November 14th, 2023
Production Dates : JAN 11, 2023 – NOV 14, 2023
VIN Range 1 : Begin : ML5ZXCP15RDA09931 End : ML5ZXCP16RDA14989 Not sequential VIN Range 2 : Begin : ML5ZXCS10RDA09911 End : ML5ZXCS10RDA14669 Not sequential VIN Range 3 : Begin : ML5ZXCS11PDA00082 End : ML5ZXCS10PDA01482 Not sequential VIN Range 4 : Begin : ML5ZXCS11RDA09951 End : ML5ZXCS13RDA13869 Not sequential VIN Range 5 : Begin : ML5ZXCS17RDA09971 End : ML5ZXCS1XRDA14209 Not sequential Description of Defect :
Description of the Defect : On certain eligible units, the spark plugs may have been damaged during the vehicle manufacturing process. It may result in unstable idle, hesitation and in the worst case, engine stalling.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : There is a risk that the engine may stall due to the damaged spark plugs,
increasing the risk of a crash. Description of the Cause : Error during installation of the spark plugs Part 573 Safety Recall Report 24V-221 Page 2 Identification of Any Warning
that can Occur : Unstable idle and hesitation Involved Components : Component Name 1 : PLUG-SPARK,LMAR9G(NGK)
Component Description : Spark plug Component Part Number : 92070-0716 Supplier Identification : Component Manufacturer
Name : Kawasaki Motors Ltd.
Address : 1-1, Kawasaki-cho
Akashi, Hyogo Foreign States 673-8666 Country : Japan Chronology :
・December 2023: Kawasaki Motors, Ltd (KML) received a report from its Chinese distributor subsidiary (KMSH) of several instances of rough idling. KMSH suspected that the cause was malfunctioning spark plugs.
KML Quality Assurance Division started an investigation of the cause.
・January 2024: Kawasaki’s spark plug supplier reported to KML that spark plugs were being cracked by an external force somehow.
・February 2024: After investigating the manufacturing process for this model, KML determined that the spark plug tightening tool was tilted during installation, applying force laterally to the spark plugs and creating the
opportunity for the spark plugs to be cracked during manufacture.
・February 2024: KML reproduced this phenomenon in testing using cracked spark plugs, which revealed that not only rough idling, but stalling could also occur.
・March 21, 2024：KML decided to initiate a recall campaign. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-221
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : All eligible units require to replace all four spark plugs. The plan of
reimbursement has been 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 :
Identify How/When Recall Condition was Corrected in Production : Add a white mark on near the engine number. From November 2023, the tool for tighten spark plug process was replaced and the spark plug tightening tool is not able to tilt when installing into the cylinder head with the new tool. Recall Schedule :
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 “Important Recall Safety Information” printed on the outside of the envelope.
Planned Dealer Notification Date : MAR 28, 2024 – MAR 28, 2024
Planned Owner Notification Date : APR 01, 2024 – APR 01, 2024
* NR – Not Reported

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