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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.
 
Does the forum have a IG page or Fakebook page? Thats a good way to direct people to the forum.
Unfortunately, those were already taken by someone else when we looked into adding them.
 
These clutch failures are continuing and getting more dangerous. Another one blew up this weekend and thankfully the driver did not have his kids in the back seat, as he said he was just cruising and heard a loud explosion, and the car stopped. He has around 300 miles on his car.

What he found was the clutch exploded, and primary clutch shrapnel went through the rear firewall and into the rear seats. Look at the pictures and see the holes and chunks of clutch in the back passenger compartment.

If Kawi does not do a recall and fix this, we will eventually see someone seriously hurt.


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Dang! That's nasty.
Glad I put our purchase on hold.
Still want the H2 but not until Kawi says they upgraded or fixed this.
 
That is gnarly. Would be curious if these failures are all on OEM clutches.
 
That is gnarly. Would be curious if these failures are all on OEM clutches.
Yes from what I gathered they have been all stock, and they all have only a few hundred miles on them. If I remember at least two people said they were not running very fast or hard when they exploded. I can’t imagine the collateral damage it might cause if you were at 7-8K rpm or running 60-70 mph when it lets go.

The good news is there is no way Kawasaki ignores or does nothing, and they have the resources and finances to fix this.
 
I tried to look for any micro fractures on my clutch casting but didn’t see any. Definitely keeping an eye on it.
 
Right Coast off road has a stronger clutch cover and talks about the cracks and towers

This is a good one too where he shows the wear between the towers and how difficult it is to put bolts back in on the cover on a worn clutch
 
I decided to order the TAPP primary & secondary (along with the tools) from Evo. Their cover mod is supposed to be available in a week or so, so it’s on order too.

Might be overly cautious on my part, but I’d rather not have to deal with getting the H2 repaired/replaced in th event of a catastrophic failure. Besides, the TAPP clutches are pretty… 🤩

I have a brand new Right Coast cover and titanium bolt set available if anyone’s interested. Just got them last week.
 
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