NHTSA vehicle safety data

2003 Kawasaki VN1600-A1 Recalls & Complaints

The 2003 Kawasaki VN1600-A1 has 3 NHTSA recall campaigns and 4 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Kawasaki dealer.

NHTSA recall and complaint data for the 2003 Kawasaki VN1600-A1. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2003 Kawasaki VN1600-A1 owner complaints

Owners have filed 4 complaints with NHTSA about the 2003 Kawasaki VN1600-A1, describing incidents dated June 30, 2005 to May 1, 2012.

Most-cited components

Fuel/Propulsion System 3 complaints
Engine 1 complaint
Power Train 1 complaint

Of the 4 complaints on file, 1 reports a fire (owner-reported, not verified by NHTSA).

Newest complaints

ODI #10459767 · Filed May 27, 2012
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…
ODI #10158180 · Filed May 24, 2006
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…
ODI #10140772 · Filed October 25, 2005
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…

Read all 4 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2003 Kawasaki VN1600-A1 in 1 investigation. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Preliminary Evaluation PE07-005: FUEL TANK LEAKS
Closed May 23, 2007
- Recall 07V-216

Open and recently closed NHTSA defect investigations

FUEL TANK LEAKS

NHTSA #07V216000 · Fuel System, Gasoline — Storage — Tank Assembly · NHTSA notice

Reported May 17, 2007 · KAWASAKI MOTORS CORP., U.S.A.

Potentially affected: 4,352 vehicles

Owners notified June 25, 2007 · Vehicles built December 13, 2002 – April 7, 2003 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

ON CERTAIN MOTORCYCLES, THE FUEL TANK IS MOUNTED TO THE CHASSIS BY MEANS OF TABS THAT ARE SPOT WELDED TO THE TANK, THEN BRAISED/WELDED AROUND A PORTION OF THEIR CIRCUMFERENCE.

Safety consequence

UNDER CERTAIN CONDITIONS, REPEATED STRESS CAN CRACK THE TANK AT THE LOCATION OF THE TABS, AND ALLOW FUEL TO LEAK.

Manufacturer remedy

DEALERS WILL REPLACE THE FUEL TANK. THE RECALL BEGAN ON JUNE 25, 2007. OWNERS MAY CONTACT KAWASAKI AT 1-866-802-9381.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATIONCUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

KAWASAKI/MUFFLER BRACKETS

NHTSA #04V063000 · Engine and Engine Cooling — Exhaust System — Manifold/Header/Muffler/Tail Pipe · NHTSA notice

Reported February 18, 2004 · KAWASAKI MOTORS CORP., U.S.A.

Potentially affected: 5,850 vehicles

Owners notified February 17, 2004 · Vehicles built October 1, 2002 – November 30, 2003 (per NHTSA)

Defect description

ON CERTAIN MOTORCYCLES, THE MUFFLER BRACKETS COULD CRACK ALLOWING THE MUFFLER TO BECOME LOOSE AND POTENTIALLY SEPARATE FROM THE MAIN EXHAUST PIPES.

Safety consequence

THIS COULD RESULT IN A CRASH.

Manufacturer remedy

DEALERS WILL REINFORCE THE MUFFLER BRACKETS. OWNER NOTIFICATION BEGAN ON FEBRUARY 17, 2004. OWNERS SHOULD CONTACT KAWASAKI AT 1-866-802-9381.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

KAWASAKI/OIL FILTER

NHTSA #04V023000 · Engine and Engine Cooling · NHTSA notice

Reported January 12, 2004 · KAWASAKI MOTORS CORP., U.S.A.

Potentially affected: 6,958 vehicles

Kawasaki campaign MC04-04 · Owners notified February 2, 2004 · Vehicles built June 1, 2002 – February 28, 2003 (per NHTSA)

Defect description

ON CERTAIN 2003 VULCAN 1500 CLASSIC, 1500 DRIFTER, 2003-2004 1500 MEAN STREAK, 2003 1600 CLASSIC, AND 2003-2004 NOMAD FL MODEL MOTORCYCLES, HIGH OIL PRESSURE UPON A COLD START-UP CAN DEFORM THE OIL FILTER CARTRIDGE.

Safety consequence

THIS COULD CAUSE OIL TO LEAK FROM THE OIL FILTER, WHICH COULD RESULT IN A CRASH.

Manufacturer remedy

DEALERS WILL REPLACE THE OIL FILTER. OWNER NOTIFICATION BEGAN ON FEBRUARY 2, 2004. OWNERS SHOULD CONTACT KAWASAKI AT 1-949-770-0400.

Notes

KAWASAKI RECALL NO. MC04-04.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

try.vin has no NCAP crash-test rating on file for the 2003 Kawasaki VN1600-A1. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

4 owner complaints have been filed with NHTSA for the 2003 Kawasaki VN1600-A1.

Fuel System, Gasoline; Fuel/Propulsion System

ODI #10459767

Incident: May 1, 2012 · Filed: May 27, 2012

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.

Power Train

ODI #10158180

Fire

Incident: March 12, 2006 · Filed: May 24, 2006

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

Engine and Engine Cooling; Fuel System, Gasoline

ODI #10140772

Incident: August 1, 2005 · Filed: October 25, 2005

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

Fuel System, Gasoline

ODI #10129511

Incident: June 30, 2005 · Filed: July 20, 2005

UNEXPECTED GAS SLEAKAGE FROM GAS TANK. NO ACCIDENT OR ANY OTHER INCIDENT TO JUSTIFY THE LEAK. TANK WILL HAVE TO BE REMOVED AND REWELDED. LEAKAGE AMOUNTS TO 1/2 TEASPOON A DAY. CONCEREND ABOUT HOUSING VEHICE IN GARAGE

Check your 2003 Kawasaki VN1600-A1 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Kawasaki VN1600-A1 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

Check a Kawasaki VIN