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Engine & cooling

Kawasaki EX500 Engine problems by year

2 complaints filed with NHTSA about the Kawasaki EX500's engine & cooling. Stalling, loss of power, oil consumption, overheating, head gaskets, timing chains and engine failure.

Engine complaints by model year

YearEngine complaintsCrashesInjuriesRecalls
19932000

Latest EX500 engine complaints

1993 Kawasaki EX500Engine & cooling

The flywheel (rotor/generator) of a 1993 kawasaki ex500, , manufactured in such a way that the magnets on the rotor itself will break apart. A licensed mechanic has told me that it could pose a possible safety hazard concerning that if part of the magnet where to become jammed it could seize the motor of the motorcycle up. This happened to me, I was only parked in my driveway, but imagine driving down the highway at highway speeds and all the sudden your motorcycle engine seizes up. This poses a series safety...

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risk not only to a motorcycle rider, but also pedestrians or other motorized people. This could result in death! In 1993 the rotor was manufactured in a way that allows the magnets to come apart due to poor/thoughtless design flaws. Now I am told that a 1994 ? Present, rotor has an inner liner that holds the magnets in place not allowing them to become loose and cause a possible seizer. I suppose ably can also purchase a brand new rotor for my motorcycle that has been redesigned to the new standard with an inner liner. I do not feel that is my responsibility to purchase this replacement part. I have a broken rotor/flywheel as we speak and they tell me it will cost be over $400.00 For a new one?! I do not think so! There needs to be a recall or a warning sent out to the dealers. People need to be aware of a threatening situation cause by poor design by kawasaki. I feel it is kawasaki?S responsibility to provide my official kawasaki dealer or myself with a replacement part at no charge. What would happen if this were one of the big three auto makers? There was a recall on a coil spring guard on my ford taurus because of the possibility of the coil spring, if broken, could puncture a tire. This flywheel/rotor issue is much more important that ! Please help anyway you can, kawasaki is not very helpful! Sincerely keith j fisher *tr

Filed Incident Engine and engine coolingNHTSA 10227695
1993 Kawasaki EX500Engine & cooling

On exhaust pipe, black paint is bubbling and peeling. Peeled hot paint flies into other riders face and eyes. Please describe details. Tt

Filed Engine and engine coolingNHTSA 969080

Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked daily. Complaints are owners' own reports and are not verified. How we use the data

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