Hey all,

Just got the Suzuki 2006 Z400 Water Pump Cover for my 2006 KFX400. The lower part bolted right up beautifully. However, the side cover part (with the large holes in it) that bolts onto the oil filter cover doesn't fit nicely. When I tighten it up, the cover pushes against the water pump inlet, forcing the cover to bow outward. Anyone suggestions?

http://www.suzukicycles.com/Accessor...1-0ffdccede901

 

Why did you replace the water pump cover?

It's the clutch covers that were having the corrosion issues.

Unless you are doing it for another reason.

But I'm not sure what you mean it won't bolt up. The WP cover bolts onto the clutch cover which bolts onto the case. The last thing you want to have in that area is ANY bowing of any metal case parts. The gasket will not set properly and you will have a serious problem.

 

Thanks for your response! Sorry, I wasn't descriptive enough. . .this is the aluminum bolt-on accessory. . .bolting it onto my nearly showroom new KFX400!

PS What do you recommend for a replacement of the clutch cover? I've heard bad things about the stock one.

 

Well the stock magnesium covers are corrosion prone.

Suzuki has now officially issued a recall on all '05/'06 clutch covers. I don't know if or when this will trickle down to Kawasaki, but try calling your dealer.

I replaced mine at the start of spring, I didn't want to wait for a recall that might not ever have come.

But you need to either use waterless coolant or to be 100% safe chance the cover over to aluminum.

 

It has already trickled down to us Kaw guys. I haven't got my letter yet but saw the info on the suzuki forum. I asked the dealer about it and he just got his copy of the recall recently. My new cover is ordered already so I'll get it before they go on backorder.