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Failing clutches.

Nikal

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I’m reading and seeing multiple H2 clutches that are catastrophically failing and in some cases literally exploding into shrapnel. And it’s both the primary & secondary’s that have been failing. The most recent one I’ve seen pictures of was a primary and it did significant damage to the car. Frame damage, radius rod damage, electrical connector damage on top of the CVT covers and CVT itself. Who knows if there is engine or crankshaft damage, as the primary clutch hangs off the crankshaft.

My guess and from seeing the Polaris XP Pro primary clutches that failed and came apart. The Polaris’s recall was due to bad castings and materials used.

My guess is Kawasaki has the same issue with bad pressure castings, machining and the material is probably to porous, and with the heat cycles it stress cracked like little spiderwebs and eventually lets go. I’d look for pitting in the H2 clutch sheaves too, as that’s a sign of oxygen within the material during the casting process, bad material and or heat treating.

Never owning a Kawasaki before, I wonder how Kawasaki handles this? How quickly to that admit their an issue and how quickly is it resolved, and how do they take care of the customers during this time. Anyone here have experience with Kawasaki or its dealers?

The cars with lower frame damage under the CVT is rally concerning as the only way to properly fix that as a OEM, is a frame replacement. You could easily cut that section out, and sleeve a new piece, or weld patch over the dent in the frame. But the OEM can’t do that, and I would not want to do that if the fault of the problem lies with the OEM’s faulty parts.
 
I saw the carnage from that clutch failure and I am betting that one of the circlips was not properly seated at the factory and it came out and then the pin and weight came loose and destroyed that clutch, the grooves are very shallow for the clips to fit in and you need to always make sure the clip is seated properly, I just don't see that much damage happening without a weight or something getting tossed around in there.
The only other failure I have seen was a blown belt that caused some damage.
 
That would be good if it’s just a clip not inserted correctly during assembly. But if the issue, they need to figure out how to eliminate that possible assembly problem.

H2 clutch failure
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Here are a few pictures of Polaris Pro XP clutches that blew up causing Polaris to recall all XP Pro’s. Like I mentioned they found it to be improper castings by Team Ind. Looks similar to how the H2 clutch looks like. If it’s not the clip & pin coming loose, could the castings be failing and throwing the pin & weight arms? Also the pictures of the H2 clutch sheaves pitting makes me think it’s material or processing.

Look at the first picture how the Polaris XP Pro casting failed and it was about ready to eject the arm.
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Well here is some great news! The guy whose H2 clutch had catastrophic failure and parts of the clutch debris hit and bent the radius rod and put a dent in the lower frame rail under the CVT clutch.

Kawasaki is going to take the car back and give him a brand new replacement car, and the whole process is taking 4 business days.

I’m glad to hear this as I wonders how Kawasaki was going to handle and respond.

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Great on Kawasaki for making it right. That's good service there!
 
Great on Kawasaki for making it right. That's good service there!
You guys need to start promoting this forum on the Fakebook and IG to get more people on here. Fakebook is for immediate gratification, but forums are a way to build up a history and is easier to search and find information. Especially on a new machine, this is the place to share info & help each other.
 
You are SO right, Nikal! A good forum community is though to beat, and can be so helpful, especially to help workout the kinks that come with new vehicles.
 
You are SO right, Nikal! A good forum community is though to beat, and can be so helpful, especially to help workout the kinks that come with new vehicles.
Does the forum have a IG page or Fakebook page? Thats a good way to direct people to the forum.
 
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