2004 Kawasaki VN2000 A1

Defect. ON CERTAIN MOTORCYCLES, THE FRONT BRAKE HOSE CAN BECOME TRAPPED BETWEEN THE FRONT FORK AND FENDER, WITH SUBSEQUENT MOTION OF THE FRONT SUSPENSION ABRADING THE BRAKE HOSE.

Risk. CONTINUED USE OF THE MOTORCYCLE WITH THE BRAKE HOSE TRAPPED IN THIS POSITION COULD CAUSE A BRAKE FLUID LEAK CREATING THE POSSIBILITY OF A CRASH RESULTING IN INJURY OR DEATH.

Remedy. DEALERS WILL ADD A BRACKET TO SUPPORT THE BRAKE HOSES, AND PREVENT THEM FROM INADVERTENTLY BEING PUSHED FORWARD INTO THE FENDER/FORK INTERFACE AREA. THE RECALL BEGAN ON AUGUST 2, 2004. OWNERS SHOULD CONTACT KAWASAKI AT 1-866-802-9381.

THIS VEHICLE HAS HAD OIL ISSUES CAUSED BY POOR DESIGN SINCE ITS INCEPTION IN 2004. THE MANUAL CALLS FOR 4.5 QTS BUT IT TAKES 6QTS TO REACH PROPER LEVEL THE DIP STICK. IT IS IMPOSSIBLE TO MAINTAIN PROPER OIL LEVEL. HAVE HAD TOP END NOISE, IGNORED BY DEALER, SINCE NEW. AT 42K MILES THE HYDRAULIC LIFTERS FAILED (8 X $60 + $900 LABOR) DUE TO LACK OF OIL. I AM TOLD BY THE DEALER THERE IS A PUMICE TYPE FILTER IN THE SYSTEM THAT CLOGS UP. THIS "FILTER" IS SUPPOSED TO LAST THE LIFE OF THE MOTORCYCLE. *TR

2004 KAWASAKI KLR 650A BROKEN TENSIONER SPRING. FAILURE FOUND AT 1700 MILE INSPECTION OF SUSPECTED BALANCER LEVER MECHANISM. NO ENGINE FAILURE OCCURRED. NEW AFTER MARKET UPGRADED PARTS AND TOOLS WERE PURCHASED AND REPAIRS WERE MADE.(BROKEN TENSIONER SPRING IS AVAILABLE FOR INSPECTION). *NM

2004 KAWASAKI VULCAN 2000 MOTORCYCLE REAR PULLEY (REAR BELT SPROCKET) BEARING FAILURE. SEE PICTURES AND SHORT .AVI MOVIE WITH SOUND AT HTTP://WWW.NEWSNOT.COM/~EMONK/PICTURES/MOTORCYCLE/VN2000/V2K_PULLEY_BEARING_BLOWOUT BEARING FAILED WHILE RIDING MOTORCYCLE SOUTH ON I-35 NEAR CLEAR LAKE, IA. SPEED WAS ABOUT 55 AT THE TIME (DUE TO RAIN). SLIGHT SHIMMY WAS MOMENTARILY FELT IN REAR OF BIKE (WHICH WENT AWAY), ALONG WITH A PERSISTENT NOISE. BEARING FAILED AT 15,400 MILES ON JUNE 20, 2005. VEHICLE WAS PURCHASED NEW IN MARCH 2004. I AM THE ONLY OWNER OF THIS VEHICLE. NO ACCIDENT OCCURRED, THOUGH I CAN SEE THIS POSSIBLY CAUSING A REAR TIRE LOCKUP AT HIGHWAY SPEEDS, WHICH WOULD SURELY CAUSE AN ACCIDENT. FROM CONVERSATIONS WITH OTHER VULCAN 2000 OWNERS (SAME MAKE/MODEL/YEAR), THIS IS BY FAR NOT THE FIRST TIME THIS KIND OF FAILURE HAS HAPPENED. ONE OWNER'S BEARING FAILED AT 10,100 MILES. SEE HTTP://ROGUEOWNERSGROUP.COM/ROGUEBUGS.ASPX AND LOOK FOR ITEM DESCRIBED AS "BEARING AND SEAL FAILURE". THERE IS A REAL POSSIBILITY THAT THIS BEARING FAILURE COULD CAUSE A REAR TIRE LOCKUP AT SPEED, WHICH IS A SERIOUS SITUATION FOR A MOTORCYCLIST TO BE IN. KAWASAKI REPLACED ORIGINAL EQUIPMENT BEARING WITH A NEW ONE UNDER A PURCHASED EXTENDED WARRANTY. IN THE NEAR FUTURE, I AM PLANNING ON REPLACING THE REPLACEMENT BEARING WITH A BOCA BEARING MR6006-2RS ($15.95), WHICH IS DOUBLE SEALED. ORIGINAL EQUIPMENT BEARING APPARENTLY ONLY HAS AN OUTSIDE DUST SHIELD. I BELIEVE WITH THE HIGH RISK OF FAILURE AND THE

DT : CONTACT STATES: MOTORCYCLE HAS BEEN IN THE SHOP A TOTAL OF 5 TIMES. AT FIRST IT WAS MAKING A RATTLING NOISE AND THEY TRIED TO FIX IT WOULD START RATTLING AGAIN. THE FRONT PULLEY QUIT WORKING. AT A CORNER OR A CURVE, AND THE PULLEY GOES OUT COULD HAVE AN ACCIDENT. *AK