true, i ordered a 04' from a company in n.c. and when i was ready to put it on i saw the letters mg stamped inside it. wasnt to happy, i went to a atv shop here in town and had them look it up and he to said there was 2 04' one was cheaper than the other . the high dollar one that i got was the magnessium, lucky me!!! so..... i had to put a $30 powdercoat job on it to make it work. so i spet about $210 on that project, thanks suz and kawi.

 

Someone make a new post to this because 6 pages is a little excessive...

 

So whats going on with this issue? Has Suzuki ever issued a recall? Are dealers covering it? I asked my dealer today and he had never heard of the problem. I'll take it in next week for em to look at.

 

Isn't that funny it's such a wide spread issue, but no one seems to know about it? Maybe half the reason there hasn't been a recall is that the dealers aren't passing the info along. I talked to 2 different dealers who claimed to have never heard of it. I had the dealer look at mine, but he said it was fine. I gave him a pic I found on here, and told him what was happening. I'll bet if someone called and asked, he'd say he never heard of it.

 

Was you quad fine or was it corroding? I pulled my cover off and its corroded just like the picture in this thread. I guess I'll be out a few bucks for an old cover.

 

5 things not to forget: Top one listed is most important to me cuz you cant rearly get the orignal out with out wrecking it.


!!! The SEAL-Oil, Crank !!!
Part number: 92049-S048 (It is held in by a little screw and clip, goes on inside of new cover. See bottem note)

COVER-CLUTCH
Part Number: 14032 (witch is a '03 aluminum clutch cover)

Bolt
Part Number: 921530S144

Gasket (washer for bolt)
Part Number: 11061-S001 Bolt and washer are for that extra hole on the outter bottem of case.

Gasket, Clutch Cover
Part Number: 11061-S071

Note: The !NEW! seal can be installed with out damage by taking a 1" PVC pipe like 4-5 inches long and tapping it in evenly with this to not bend or twist the seal.


Why I typed these numbers I was looking at the orginal packedge with the part number listed on the plastic. So I would assume they are all correct.


Im not trying to plug in for anyone. (Dont know if this is allowed or not) But you can get this stuff from a dealer or bikebandit.com has it. But its more diffacult on bikebandit cuz you got to go through the scumatics to find the parts and add them to your cart. Selecting the right year bike. (Would need to select a '03 KFS/KFX 400 A1)

hope this will help someone furthure on.

Phyro.

 

Saturday, a dealership talked me into buying a brand new '06 z400 (went to buy an '05 Trx450r), and I get on this forum this morning and found this potential major problem. I have a 4 yr warranty, but do not want to ruin a perfectly good bike if I can fix it now.

So, you guys are posting that Suzuki has not addressed this problem?

Thanks!

Chips2000

 

the dealership will fix underwarrenty. but if its out and then you take it up there they will not cover it. mine was 5 months out when i found out about it in dec. , my dealer said he never heard of it but his mechanic was sitting there with a big grin!!! he told me i'd have to call kawi and if they would cover it he'd get right on it , kawi said f-u its out of warrenty. i called them 7 days in a row and gave them hell all 7 days. i said if my motot blows because of this then what they said its on you. as long as its not a saftey issue these companies wont recall-i.e. 01' raptor tranny.

 

Phyroinstinct, thanks for the detailed info. It'll sure make getting the right parts easier. Too bad Suzuki isn't backing their product...

 

Hate to tell ya, but the powder coat will not solve your problem. It will return over time. [img]i/expressions/face-icon-small-sad.gif[/img]

Ask the cannondale guys. They've all been through this already. Your only guarenteed fix is to buy an aluminum cover, or buy Evan's waterless coolant.