2003 Kawasaki VN1600-A1

Defect. ON CERTAIN MOTORCYCLES, THE FUEL TANK IS MOUNTED TO THE CHASSIS BY MEANS OF TABS THAT ARE SPOT WELDED TO THE TANK, THEN BRAISED/WELDED AROUND A PORTION OF THEIR CIRCUMFERENCE.

Risk. UNDER CERTAIN CONDITIONS, REPEATED STRESS CAN CRACK THE TANK AT THE LOCATION OF THE TABS, AND ALLOW FUEL TO LEAK.

Remedy. DEALERS WILL REPLACE THE FUEL TANK. THE RECALL BEGAN ON JUNE 25, 2007. OWNERS MAY CONTACT KAWASAKI AT 1-866-802-9381.

Defect. ON CERTAIN MOTORCYCLES, THE MUFFLER BRACKETS COULD CRACK ALLOWING THE MUFFLER TO BECOME LOOSE AND POTENTIALLY SEPARATE FROM THE MAIN EXHAUST PIPES.

Risk. THIS COULD RESULT IN A CRASH.

Remedy. DEALERS WILL REINFORCE THE MUFFLER BRACKETS. OWNER NOTIFICATION BEGAN ON FEBRUARY 17, 2004. OWNERS SHOULD CONTACT KAWASAKI AT 1-866-802-9381.

Defect. ON CERTAIN 2003 VULCAN 1500 CLASSIC, 1500 DRIFTER, 2003-2004 1500 MEAN STREAK, 2003 1600 CLASSIC, AND 2003-2004 NOMAD FL MODEL MOTORCYCLES, HIGH OIL PRESSURE UPON A COLD START-UP CAN DEFORM THE OIL FILTER CARTRIDGE.

Risk. THIS COULD CAUSE OIL TO LEAK FROM THE OIL FILTER, WHICH COULD RESULT IN A CRASH.

Remedy. DEALERS WILL REPLACE THE OIL FILTER. OWNER NOTIFICATION BEGAN ON FEBRUARY 2, 2004. OWNERS SHOULD CONTACT KAWASAKI AT 1-949-770-0400.

FUEL TANK STARTED TO LEAK WHILE SITTING IN GARAGE, FUEL WAS PUDDLING ON THE FLOOR. FURTHER INVESTIGATION REVEALED THAT THE TANK WAS LEAKING WHERE THE MOUNTING PLATE IS ATTACHED TO THE FUEL TANK. CORRESPONDS WITH RECALL #07V216000 ISSUED IN JUNE 2007. A VIN SEARCH ON KAWASAKI'S WEBSITE RESULTED IN A NOTICE THAT THIS VEHICLE WAS NOT AFFECTED BY THE RECALL, HOWEVER THE TANKS IS LEAKING AS DESCRIBED BY THE MENTIONED RECALL.

WHILE TRAVELING AT 65+ MPH ON I-64, A FRIEND RIDING BEHIND ME NOTICED SMOKE COMING FROM MY MOTORCYCLE AND SIGNALED FOR ME TO PULL OVER. WHEN I GOT TO THE SIDE OF THE SHOULDER I NOTICED THAT THE SMOKE WAS COMING FROM BEHIND THE COVER ON THE LEFT SIDE OF THE ENGINE/TRANSMISSION JUST FWD OF THE DRIVE SHAFT. I COULD SEE THE GLOW OF FLAMES STILL BURNING THROUGH THE HOLE WHERE THE WIRING HARNESS PASSES. THE FIRE KEPT BURNING FOR SEVERAL MINUTES AS I TRIED TO PUT IT OUT BY SMOTHERING IT WITH A RAG. MY FRIEND CALLED THE STATE POLICE WHILE I DISCONNECTED THE BATTERY AND THEY ARRIVED WITH AN AMBULANCE AND FIRE TRUCK, BUT JUST AFTER THE FIRE BURNED ITSELF OUT. AFTER REMOVING THE COVER, I FOUND THE HARNESS COMPLETELY FRIED AND MELTED INSULATOR ALL OVER EVERYTHING. TAKING THE BIKE INTO THE DEALER FOR EVALUATION AND REPAIR TUESDAY. *JB

I WAS TRAVELING NORTH ON STATE ROAD 17 FROM DAYTON BIKE WEEK WHEN MY KAWASAKI VULCAN 1600 STARTED TO MAKE A HIGH PITCHED WINDING NOISE THEN THE COVER JUST BEFORE THE DIVE SHAFT SHOOT OFF IN TO THE TRAFFIC BEHIND ME, THEN THE MOTOR CYCLE CAUGHT FIRE. I PULLED OF THE ROAD AND A BYSTANDER HAD SOME WATER IN A COOLER WE EXTINGUISHED THE FIRE, I PUT MY BIKE IN THE SHOP AT JACKSONVILLE POWER SPORT IT WAS THERE FOR ABOUT A MONTH THEY SAID ALL THEY COULD DO WAS REPLACE THE WIRING HARNESS WHICH CAME OUT TO OVER $900.00 NOW ITS AT ANOTHER KAWASAKI SHOP IN JACKSONVILLE AND THEY ARE HAVING PROBLEMS FIXING IT TO. SO FAR THEY HAVE CHANGED THE FINAL GEAR DRIVE AND NOW THEY SAY IT MIGHT BE A BEVEL GEAR THAT IS NOT LINED UP RIGHT. *JB

DT: THE CONTACT STATED THAT THERE WAS A HAIRLINE CRACK IN THE FUEL TANK. HE FIRST NOTICED THE PROBLEM BECAUSE OF THE SMELL OF LEAKING FUEL. ALSO, WHERE THE EXHAUST PIPE BRACKET CONNECTS TO THE MUFFLER WAS WEAK FROM STRESS CRACK FAILURES. THERE WAS A RECALL FOR THE EXHAUST PIPE ISSUE, WHICH WAS REPAIRED UNDER THE RECALL. NOW, THE EXHAUST PIPE HAS A WELDING PROBLEM. *AK

UNEXPECTED GAS SLEAKAGE FROM GAS TANK. NO ACCIDENT OR ANY OTHER INCIDENT TO JUSTIFY THE LEAK. TANK WILL HAVE TO BE REMOVED AND REWELDED. LEAKAGE AMOUNTS TO 1/2 TEASPOON A DAY. CONCEREND ABOUT HOUSING VEHICE IN GARAGE