clutch cover failures- '05 & '06 LTZ/KFX/DVX 400 owners LOOK HERE!!!

[apkkfx400]

If this has already been posted I apologize-but mods please make this a pinned/sticky topic!!!

check out this info at this website-be prepared-this sucks!


http://www.z400central.com/invision/index.php?showtopic=52767&st=750

Before I put my exhaust on and drained the coolant, my coolant was discolored.  Once I get out of work tonight, I'm going to check mine out and I'll let y'all know!

Mark

[eric]

Let me know what you find. Here is what one person from z400central sent to Suzuki




If you want to send a letter to Suzuki, please send it to the attention of Brad Wright. He is the manager at the customer service department. If all the letter go across the same desk, it would help.

In case you need an idea of what the letter should say, here is what I am sending to them. Feel free to cut and paste to suit your needs!

December 13th, 2005

Dear Suzuki,

I am the owner of a 2005 LT Z400, VIN ( your VIN here ). It was purchased in March of this year. I recently learned about a problem where the magnesium clutch cover is deteriorating due to the incompatibility with the factory coolant.

I inspected my Z400 on 12/9/05 and discovered the same problem ALL the 2005 LT Z400’s and KFX400’s are facing. Thus far, there have not been ANY owners of the 2005 models that did not report deterioration to some degree. If left unchecked, the coolant will eventually leak into the engine oil and cause catastrophic damage to the engine.

I feel that this issue that MUST warrant a recall. There are several online forums I have been checking in reference to this problem. There are many very unhappy LTZ and KFX owners demanding that Suzuki addresses this issue and declares this to be a manufacturing defect. Either the clutch cover should not be made of magnesium, or the factory should use coolant which does not react with magnesium.

Here are a few of URL’s I recommend you visit:

Here is a picture of my own quad.
http://members.cox.net/craven_morehead/quad/clutchcover.jpg

Here is a link to the Z400 Central forum discussing the topic. Please note that there are over 5000 views of this forum and countless pictures and complaints of owners finding the same problem.
http://www.z400central.com/invision/index....showtopic=52767

Here is a link to the Glamis Dunes forum discussing the topic.
http://www.glamisdunes.com/invision/index....showtopic=61754

Other owners are spreading the word to ATV magazines and other online forums. This issue will continue to gain more attention as word spreads for everyone to inspect their quads. The right thing for Suzuki to do is to show that they stand behind their product 100%. I had several choices when deciding which quad to buy. I sincerely hope you do not make me regret choosing Suzuki over your competitors. Your actions on this issue will determine my future ATV purchases as well.

My quad is currently in the service department at Town and Country Motorsports in Chandler, Arizona for this issue. Please have someone contact me directly. I would like to be continually updated as to what Suzuki plans to do.


Sincerely,




Name
Address
Phone
Email address

[apkkfx400]

Called Kawasaki consumer service and they advised me to take into the dealer which I purchased it from.  They did advise to not take the clutch cover off and to have the dealer contact them when they did.  I took it into today and let the service consultant know the details of the problem-he had not heard of this concern before-so I'll post any info as it comes to me!!

[TRX450R_Racer]

One of my friends has a 2005 Z400. He has had it since January 05. Luckily I'm a nut when it comes to not being able to leave anything a lone. The week he brought it home we drained and flushed the cooling system and filled it with Engine Ice. Hopefully it won't react with the cover. I'm going to call Engine Ice on the issue and see what they have to say.

[eric]

http://www.petitiononline.com/696z400/petition.html

[eric]

Took mine to Cycle Riders in Longwood today. The technician said I was not the first person to bring in a z400 for this reason. He asked me if I had seen any discoloration in my coolant as this would mean more serious problems were already in affect. They did not tell me if everything would be covered as far as costs but said later this week they would open it up the see if there is any damage and take pics and report it to the factory to see. I am just sort of amazed that no Suzuki owners are being notified about this but we are finding out through atv forums online

[apkkfx400]

Well I figure the manufacturer(s) are trying to come up with a cheap and quick way to fix this issue but could be making the issue worse by taking so long to come up with that fix!!  I dropped mine off last Tuesday and has yet to be looked at-service dept is slammed.

[eric]

Wonder how long before the people who don't know start to have major problems or see their motors start blowing up?

[kfx400rob]

last time i changed my oil i saw no coolent in it

[apkkfx400]

last time i changed my oil i saw no coolent in it

.

If it has a magnesium cover-which it does, you have a problem.  The dealership called me late Friday to tell me they were waiting to hear back from Kawasaki to find out what is covered and how to submit for warranty being that I'm about 8 months out of factory warranty.

[apkkfx400]

Found out yesterday they (dealership/Kawasaki) are replacing the magnesium clutch cover with an aluminum cover due to erosion on the inside of the clutch cover.  They won't have it done 'til next week but better than finding out the problem when the coolant mixes w/the oil and leaves ya stranded somewhere.

[kfx400rob]

is it just the facory coolent thats doing that? cuz i changed my coolent about three months after i got mine to put the new pipe on and iv had no problems

and my brother replaced the clutch on his recently and there was no problems in there.

and we both have the magnesium cover

[Chevy1500z71]

yea, i just put a new clutch in and the coolent didnt eat threw...

[TRX450R_Racer]

Found out yesterday they (dealership/Kawasaki) are replacing the magnesium clutch cover with an aluminum cover due to erosion on the inside of the clutch cover.  They won't have it done 'til next week but better than finding out the problem when the coolant mixes w/the oil and leaves ya stranded somewhere.

How long have you had you quad?

[apkkfx400]

Bought in February '05.

[TRX450R_Racer]

Does anyone have the part # for the updated aluminum plate?

[eric]

OK, I called Suzuki today and they took mine apart. Said there was no problem with anything so I should have mine back by Monday. I might change out the anti-freeze to one that is compatable with magnesium to be safe.

[apkkfx400]

Just a heads up Eric-Cycle sports center took mine apart and didn't find anything.  I work less than 5 min from that dealership and drove down while they had it apart-sure enough they was erosion on the clutch plate cover (not sure why they didn't find it).  They are still waiting for the aluminum clutch cover to come in but Kawasaki said to replace it under warranty!!

[greenmachine]

Does anyone know if this affects the 2003 models?

[apkkfx400]

No, it doesn't affect '03-the 2003 models came with an aluminum clutch cover-'05 and '06 comes with a magnesium clutch cover and that's what they are replacing the 2005 and '06 models.

[Chevy1500z71]

so kawi will gime an aluminum 1 for free, my warenty is up but is it under recal... mine is an 05

[apkkfx400]

so kawi will gime an aluminum 1 for free, my warenty is up but is it under recal... mine is an 05

You've got to call Kawasaki-you'll have to check the phone # on Kawasaki website-it's not a recall at this time.

[Chevy1500z71]

so kawi will gime an aluminum 1 for free, my warenty is up but is it under recal... mine is an 05

You've got to call Kawasaki-you'll have to check the phone # on Kawasaki website-it's not a recall at this time.

ok, well whene i changed my clutch out it seemed fine but its not that old, it mite still carode? idk ill call them and c if i can get one for free

[TRX450R_Racer]

I will be taking my friends 05 Z400 a part this week. I will post my findings.

[eric]

Just a heads up Eric-Cycle sports center took mine apart and didn't find anything.  I work less than 5 min from that dealership and drove down while they had it apart-sure enough they was erosion on the clutch plate cover (not sure why they didn't find it).  They are still waiting for the aluminum clutch cover to come in but Kawasaki said to replace it under warranty!!

You were right Mark. The service department manager called me today and said after everything had dried up and they were about to put it back together they noticed corrosion. The part will be in next week but they said I would have to pay for about 2 hrs of labor or around $150. Were you charged for labor as well?

[TRX450R_Racer]

I took my buddys a part yesterday. We put Engine Ice in it the week he got it. The corrosion is started but not as bad as I have seen with the factory coolant & water mix. I spoke withe the Enigine Ice poeple and was told you have to change the cover or go with Evans coolant because it has no water in it. If you decid to not change the cover you must flush the system 3 times with 50% vinegar & 50% water. Then you must dry the system completely before you add the Evans. I personally think the cover should be changed for paece of mind. Here is a picture of my friends 05 Z400. It is 16 months old.
 

[attachment deleted by admin]

[apkkfx400]

Eric, the last time I heard it was being covered by Kawasaki in full.  But we'll see when they finally receive the part.  Aluminum clutch is on backorder and has been for almost 2 wks. 

[apkkfx400]

Well, the call came in today-she is finally done.  I'll be picking it up tomorrow-can't wait to go riding-been over a month now.

[eric]

Well, the call came in today-she is finally done.  I'll be picking it up tomorrow-can't wait to go riding-been over a month now.

Glad to hear you're getting her back    Mine is supposed to be done Wed. Mark please let me know if they charge you for labor as Suzuki is trying to get me to pay. Thanks

[MotoMike]

Okay, that means its my turn...lol

I just picked up my 05, thankfully, no ride time on it.  Hopefully no damage yet.  Any idea if it is hard to change yourself.  That last thing I want to do right now is have it sit at a dealer ship for weeks.

Thanks for the heads up Mark.  Hey Eric, wanna go riding?  lol

Mike

[apkkfx400]

You can look around for the aluminum clutch cover-the dealership only had to hold on to mine because the part was on backorder.  I'm guessing that's what you're going to have problems with-finding/getting the part.

[TRX450R_Racer]

The 2004 cover is readily available, I got all the parts I needed for Delray Powersports for less than $120 to do my friends 2005. He had Engine Ice in there from day 1, there was still some corrosion and a lot of crap in the cooling system. I fell sorry for you guys that have the stock coolant. Good Luck

[eric]

Okay, that means its my turn...lol

I just picked up my 05, thankfully, no ride time on it.  Hopefully no damage yet.  Any idea if it is hard to change yourself.  That last thing I want to do right now is have it sit at a dealer ship for weeks.

Thanks for the heads up Mark.  Hey Eric, wanna go riding?  lol

Mike

NO, u didn't just buy another quad. You have no brand loyalty thats for sure

[MotoMike]

I have brand loyalty, just gotta try them all to find out which I like best...lol

Mike

[TRX450R_Racer]

If anyone doesn't want to have the dealer do the job, I can do it for you. I'm very reasonable and can do it while you wait. No down time. I can supply the parts or you can.

[MotoMike]

Where are you located?  I found the cover, how much for the gasket and oil?

Mike

[Toomey]

If anyone doesn't want to have the dealer do the job, I can do it for you. I'm very reasonable and can do it while you wait. No down time. I can supply the parts or you can.

He did a big job on my RM, don't be skeptical or worried in the least.  He's a one of a kind guy who's got the tools and know-how and is just helping out.  Awesome way of living man.

[apkkfx400]

Saturday, after I got home from riding in ONF.  I came home to find a safety recall on my '05 Kawasaki for the clutch cover issue that stated they would absorb the cost of the repairs=parts/labor.  If you haven't done the repair, I would recommend calling Kawasaki and finding out if they will cover it.  But if you have more money then time, I guess do it yourself.

[TRX450R_Racer]

Thanks for the info. I will see if Suzuki is stepping up also. Is there a recall number on the letter?

[apkkfx400]

Thanks for the info. I will see if Suzuki is stepping up also. Is there a recall number on the letter?

I'm at work and the letter is sitting at home-there is a recall #-I will post that and the contact phone # to Kawasaki tomorrow.

[TRX450R_Racer]

Thanks for the info. I will see if Suzuki is stepping up also. Is there a recall number on the letter?

I'm at work and the letter is sitting at home-there is a recall #-I will post that and the contact phone # to Kawasaki tomorrow.

Thanks

[TRX450R_Racer]

My buddy got the recall letter from Suzuki today.  WOOOOO HOOOO!! No he can get his money back.

[blaster30]

I just bought a used Z-400 and I noticed that on the Suzuki site in the upper right hand corner there is a link to Recalls. http://www.suzukicycles.com/Recalls/16.  I called the local dealer and she looked up the vin and told me that the bike had this recall applied, but there was another recall on it.  She is getting the details about it and will call me back.  I will update when I have the information.

Thanks!!

[TRX450R_Racer]

What year is yours?