I got this email from another forum. Has anybody heard of this?
The corrosion problem just surfaced. Suzuki learned about it two weeks ago and they are reportedly conducting a "confidential" investigation. After reading about numerous other people that were having the problem at z400central.com, I pulled the water inlet cover today on my '05 Z400 and discovered that the magnesium cover was badly corroded and pitted. If it corrodes all the way through, it will dump coolant into the engine.
What you need to do is remove the four bolts to the water inlet next next to the oil filter, and loosen the clamp and pull off the water hose. Once the bolts are removed, work the cover backwards about 1/2 inch (it won't come off unless you remove the whole clutch cover) and rotate it to the right. This will expose the water inlet so that you can inspect it. When you reinstall it, use distilled water and ATV coolant.
If you are under warranty, you will want to take it the dealer. If you are out of warranty (like me), you might want to contact Suzuki customer service or make a claim with Suzuki through your dealer. The only know fix is to buy an '04 aluminum cover for now.
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