Kawasaki Recalls Nearly 3,750 Motorcycles Over Clutch Defect

Kawasaki Motors Corp., U.S.A. has issued a safety recall affecting 3,742 motorcycles due to a defect in the clutch release shaft that could lead to vehicle disablement and an increased risk of crashes. The recall impacts specific 2024 model-year Z500 ABS, Z500 SE ABS, and Ninja 500 motorcycles, including various ABS and special edition versions, produced between January 22, 2024, and February 6, 2024.

According to Kawasaki, the defect stems from an improper weld between the clutch release shaft and the clutch release lever. If the component fails, riders may experience difficulty disengaging the clutch, potentially rendering the motorcycle inoperable. Kawasaki estimates that approximately 1% of the recalled units may have this defect. The faulty part was supplied by New Somthai Motor Work Co., Ltd, based in Thailand.

The issue was first identified in May 2024 when Kawasaki received reports of a worsening clutch lever feel in an EX500G model. Further investigation revealed that some motorcycles may have been assembled with “trial parts” from a welding machine that was improperly set. By February 2025, Kawasaki determined that the welding defect was present in certain models and initiated the recall.

To remedy the issue, Kawasaki will replace the clutch release shafts on all affected units. Owners who previously paid for related repairs may be eligible for reimbursement by submitting documentation to Kawasaki Motors Corp., U.S.A. Dealer and owner notifications are scheduled for March 20 and March 24, 2025, respectively. Owners with affected motorcycles are advised to contact their dealer for a free repair.

Article by multiple RFHC contributors, based upon information from Kawasaki Motors Corp., U.S.A.

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