Heard of some people on here having some trouble. But I have ran the dog piss out of mine for about 30-40hrs on it total. That includes wide open dune riding, hill climbing back east, and hard riding through trails. Change oil after every ride and check wire harness after every couple rides. Never had any trouble with mine. Still runs strong. Only trouble I had was the tail light fell off and the frame rubbed the wire enough to blow a fuse. But that was the dealer fault as the tail light was over tightened.
Good luck fixing them. Lol. You can't weld them b/c they are steel in an aluminum frame and if you buy new ones they'll be loose still after being put in. Only way to try to fix them is to work some JB weld in all the way around the edge, but that won't hold up for long and you can't fully tighten them.+1 I have to agree,
The previous owner spun 5 of the inserts so that is on my list of things to fix.
Is that all...!!! I'm glad I bought me one...Lol..!!!1. Wiring harness rubs and shorts out
2. OEM ECU causes battery drain in many units and is not something Kawi is willing to re-call
3. Roll-over sensor is worthless and needs to be bypassed
4. Stock intake design is miserable
5. Throttle position sensor can cause issues if not adjusted right
6. Stock header cracks and blows up due to heat and vibration
7. Most are toed improperly from the factory (need 1/8" in per side from what I like)
8. The lower steering stem bearing goes out and is expensive to replace
9. The frame and subframe nut inserts spin in the frame and don't let you tighten/losen bolts
10. Shocks are really rough in stock form
11. Stock seat is hard as a rock
12. Crank and connecting rod is weak if you consider going to a hi-comp piston
13. Several people have busted cases when switching to reverse when high centered w/wheels spinning slowly
14. Rear sprocket bolts shear and cause the chain to bust the case unless you have a poly case saver and are watchful of the bolts.
15. Spindles are weak where the tie rod ends attach and break.
16. Front bumper mounts are weak, so if you run anything stronger than an OEM bumper you will mess them up (crack or break the lowers) at the first small impact.
17. Brake light switch on front master cylinder shorts out and causes the main fuse to flow
18. Did I mention that IF you have a problem, the electrical system is HARD to troubleshoot
Hate to make it sound like a horrible quad, but I had mine since 07 and there were plenty of things that went wrong and I've been around with everyone else complaining. Know plenty of die hard Kawi guys like me that finally just gave up on it. The motor is strong, but honestly this quad takes just about the most money to get it ready to race in comparison to the other 450's (other than the KTM of course w/the high initial investment and horrible maintenance).