2003 Kawasaki VN1600-A1 Problems
Owner-reported complaints filed with NHTSA, grouped by component
Data refreshed
What this page shows
Everything below is an owner-reported complaint submitted to NHTSA about the 2003 Kawasaki VN1600-A1, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.
Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.
Reports by component
Ranked by how many owner reports name each component category
- Fuel system337.5%
- Powertrain (other)225.0%
- Electrical112.5%
- Engine112.5%
- Transmission112.5%
Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.
Each component in detail
What the reports in each category say, in the owners' own words
Fuel system
Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.
From owner reports, verbatim
FUEL TANK STARTED TO LEAK WHILE SITTING IN GARAGE, FUEL WAS PUDDLING ON THE FLOOR. FURTHER INVESTIGATION REVEALED THAT THE TANK WAS LEAKING WHERE THE MOUNTING PLATE IS ATTACHED TO THE FUEL TANK. CORRESPONDS WITH RECALL #07V216000 ISSUED IN JUNE 2007. A VIN SEARCH ON KAWASAKI'S WEBSITE RESULTED IN A NOTICE THAT THIS VEHICLE WAS NOT AFFECTED BY THE RECALL, HOWEVER THE TANKS IS LEAKING AS DESCRIBED BY THE MENTIONED RECALL.
DT: THE CONTACT STATED THAT THERE WAS A HAIRLINE CRACK IN THE FUEL TANK. HE FIRST NOTICED THE PROBLEM BECAUSE OF THE SMELL OF LEAKING FUEL. ALSO, WHERE THE EXHAUST PIPE BRACKET CONNECTS TO THE MUFFLER WAS WEAK FROM STRESS CRACK FAILURES. THERE WAS A RECALL FOR THE EXHAUST PIPE ISSUE, WHICH WAS REPAIRED UNDER THE RECALL. NOW, THE EXHAUST PIPE HAS A WELDING PROBLEM. *AK
Too few reports in this category for a page of its own — they appear in the full complaint list.
Powertrain (other)
Powertrain reports that are not specifically the engine or transmission — driveshafts, axles, transfer cases and differentials.
From owner reports, verbatim
WHILE TRAVELING AT 65+ MPH ON I-64, A FRIEND RIDING BEHIND ME NOTICED SMOKE COMING FROM MY MOTORCYCLE AND SIGNALED FOR ME TO PULL OVER. WHEN I GOT TO THE SIDE OF THE SHOULDER I NOTICED THAT THE SMOKE WAS COMING FROM BEHIND THE COVER ON THE LEFT SIDE OF THE ENGINE/TRANSMISSION JUST FWD OF THE DRIVE SHAFT. I COULD SEE THE GLOW OF FLAMES STILL BURNING THROUGH THE HOLE WHERE THE WIRING HARNESS PASSES. THE FIRE KEPT BURNING FOR SEVERAL MINUTES AS I TRIED TO PUT IT OUT BY SMOTHERING IT WITH A RAG. MY FRIEND CALLED THE STATE POLICE WHILE I DISCONNECTED THE BATTERY AND THEY ARRIVED WITH AN AMBULANCE AND FIRE TRUCK, BUT JUST AFTER THE FIRE BURNED ITSELF OUT. AFTER REMOVING THE COVER, I FOUND THE HARNESS COMPLETELY FRIED AND MELTED INSULATOR ALL OVER EVERYTHING. TAKING THE BIKE INTO THE DEALER FOR EVALUATION AND REPAIR TUESDAY. *JB
I WAS TRAVELING NORTH ON STATE ROAD 17 FROM DAYTON BIKE WEEK WHEN MY KAWASAKI VULCAN 1600 STARTED TO MAKE A HIGH PITCHED WINDING NOISE THEN THE COVER JUST BEFORE THE DIVE SHAFT SHOOT OFF IN TO THE TRAFFIC BEHIND ME, THEN THE MOTOR CYCLE CAUGHT FIRE. I PULLED OF THE ROAD AND A BYSTANDER HAD SOME WATER IN A COOLER WE EXTINGUISHED THE FIRE, I PUT MY BIKE IN THE SHOP AT JACKSONVILLE POWER SPORT IT WAS THERE FOR ABOUT A MONTH THEY SAID ALL THEY COULD DO WAS REPLACE THE WIRING HARNESS WHICH CAME OUT TO OVER $900.00 NOW ITS AT ANOTHER KAWASAKI SHOP IN JACKSONVILLE AND THEY ARE HAVING PROBLEMS FIXING IT TO. SO FAR THEY HAVE CHANGED THE FINAL GEAR DRIVE AND NOW THEY SAY IT MIGHT BE A BEVEL GEAR THAT IS NOT LINED UP RIGHT. *JB
Too few reports in this category for a page of its own — they appear in the full complaint list.
Electrical
Reports naming the electrical system — wiring, battery, charging, control modules, infotainment and electrical accessories.
From owner reports, verbatim
WHILE TRAVELING AT 65+ MPH ON I-64, A FRIEND RIDING BEHIND ME NOTICED SMOKE COMING FROM MY MOTORCYCLE AND SIGNALED FOR ME TO PULL OVER. WHEN I GOT TO THE SIDE OF THE SHOULDER I NOTICED THAT THE SMOKE WAS COMING FROM BEHIND THE COVER ON THE LEFT SIDE OF THE ENGINE/TRANSMISSION JUST FWD OF THE DRIVE SHAFT. I COULD SEE THE GLOW OF FLAMES STILL BURNING THROUGH THE HOLE WHERE THE WIRING HARNESS PASSES. THE FIRE KEPT BURNING FOR SEVERAL MINUTES AS I TRIED TO PUT IT OUT BY SMOTHERING IT WITH A RAG. MY FRIEND CALLED THE STATE POLICE WHILE I DISCONNECTED THE BATTERY AND THEY ARRIVED WITH AN AMBULANCE AND FIRE TRUCK, BUT JUST AFTER THE FIRE BURNED ITSELF OUT. AFTER REMOVING THE COVER, I FOUND THE HARNESS COMPLETELY FRIED AND MELTED INSULATOR ALL OVER EVERYTHING. TAKING THE BIKE INTO THE DEALER FOR EVALUATION AND REPAIR TUESDAY. *JB
Too few reports in this category for a page of its own — they appear in the full complaint list.
Engine
Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components.
From owner reports, verbatim
DT: THE CONTACT STATED THAT THERE WAS A HAIRLINE CRACK IN THE FUEL TANK. HE FIRST NOTICED THE PROBLEM BECAUSE OF THE SMELL OF LEAKING FUEL. ALSO, WHERE THE EXHAUST PIPE BRACKET CONNECTS TO THE MUFFLER WAS WEAK FROM STRESS CRACK FAILURES. THERE WAS A RECALL FOR THE EXHAUST PIPE ISSUE, WHICH WAS REPAIRED UNDER THE RECALL. NOW, THE EXHAUST PIPE HAS A WELDING PROBLEM. *AK
Too few reports in this category for a page of its own — they appear in the full complaint list.
Transmission
Reports naming the automatic or manual transmission, including shifting behaviour, shudder, slipping and transmission control modules.
From owner reports, verbatim
I WAS TRAVELING NORTH ON STATE ROAD 17 FROM DAYTON BIKE WEEK WHEN MY KAWASAKI VULCAN 1600 STARTED TO MAKE A HIGH PITCHED WINDING NOISE THEN THE COVER JUST BEFORE THE DIVE SHAFT SHOOT OFF IN TO THE TRAFFIC BEHIND ME, THEN THE MOTOR CYCLE CAUGHT FIRE. I PULLED OF THE ROAD AND A BYSTANDER HAD SOME WATER IN A COOLER WE EXTINGUISHED THE FIRE, I PUT MY BIKE IN THE SHOP AT JACKSONVILLE POWER SPORT IT WAS THERE FOR ABOUT A MONTH THEY SAID ALL THEY COULD DO WAS REPLACE THE WIRING HARNESS WHICH CAME OUT TO OVER $900.00 NOW ITS AT ANOTHER KAWASAKI SHOP IN JACKSONVILLE AND THEY ARE HAVING PROBLEMS FIXING IT TO. SO FAR THEY HAVE CHANGED THE FINAL GEAR DRIVE AND NOW THEY SAY IT MIGHT BE A BEVEL GEAR THAT IS NOT LINED UP RIGHT. *JB
Too few reports in this category for a page of its own — they appear in the full complaint list.
Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.
Elsewhere on this vehicle
Data sources
- NHTSA Office of Defects Investigation — owner-reported complaints and the components recorded on them
Data on this page last refreshed .