Kawasaki Recalls 3,742 Motorcycles Over Clutch Release Shaft Issue

Kawasaki Motors U.S.A. has issued a voluntary recall for 3,742 units of the 2024 Kawasaki Z500 and Ninja 500 series due to a defect in the clutch release shaft that were manufactured between January 22, 2024 and February 6, 2024.

According to the report filed by Kawasaki to NHTSA said, On certain eligible units, the clutch release shaft was not properly welded between the lever and the shaft. Continuous use in this condition may result in the lever coming apart, making it difficult to disengage the clutch and thereby disabling the vehicle.

If the clutch release lever fails while riding, the motorcycle may become inoperable, increasing the risk of an accident. Kawasaki has attributed the defect to the use of improperly welded "trial parts" during assembly.

In May 2024 Kawasaki Motors received a report of worsening clutch lever feeling in an EX500G. In October 2024 KML received a report from its Japanese distributor subsidiary (KMJ) of clutch failure on a EL400A while riding. KML Quality Assurance Division contacted its supplier again to further investigate. In Jan 2025 KML found the cause of this potential issue was the improper setting of the welding machine by the supplier.

To deal with the issue Kawasaki will replace the faulty clutch release shafts free of charge. Affected owners will be notified by mail starting March 24, 2025. Dealers will also receive service bulletins regarding the recall. Customers who have already paid for repairs may be eligible for reimbursement.

Owners of the affected motorcycles should contact their nearest Kawasaki dealership for a free replacement. They can also reach out to Kawasaki Motors Corp., U.S.A. for more details regarding the recall process.