69 of the
229 complaints filed about the Kawasaki KLR650
are about the engine —
30% of everything owners reported.
The worst model year for it is 2001.
The contact owns a 2024 Kawasaki KLR650. The contact stated that while riding approximately 2-3 MPH, the ABS engaged independently. The contact stated that there was an ABS module failure as well. No warning light was illuminated. The contact stated that the motorcycle downshifted unexpectedly without the clutch being activated. An independent mechanic was contacted. The contact exited the motorcycle and walked the motorcycle to the closest shop. The motorcycle was taken to an independent mechanic, where it was diagnosed, and determined that the brake fluid needed to be changed. The contact stated that the failure reoccurred. The manufacturer was not notified of the failure. The approximate failure mileage was 86,000.
NHTSA complaint #11694562 — an unverified report by a vehicle owner.
Steering bearing overtorqued by factory, dealer warranty loostened and readjusted, initial tendency, failure to return to neutral, rough bearing feeling, caused many near misses with vehicles ahead, problem unresolved, I can feel it, dealer can not. Contra Costa Powersports, 1150 Concord Ave Ste 100, Concord, CA 94520 (925) 687-7742. Issue regarding drive train, false neutral. Potentially hazardous conditions occurred three times. Pulled over to adjust GPS, engine running, shifted to neutral, neutral light illuminated on dash, put the side stand down,, released the clutch bike still in gear, bike lunged forward, off of sidestand, bike headed for ground with rider, lucky first two times I had my hand on the front brake, lock up brake preventing bike from launching off the side stand and crashing to ground. First time with stock clutch and brake levers set up by dealer with 1/16 clutch free play, third time with Warp9 aftermarket adjustable brake and clutch levers, was in same 1/16" free play when set up, cable seated during 100 mile ride, gap then 1/4", third false neutral, dash displayed green neutral indication light, side stand down, released clutch, bike still in gear, this time hand not on brake lever, didn't anticipate bike movement, the bike launched forward off the sidestand, tried to eject me into the roadway. Could have been lethal consequences had I not recovered the bike before it dropped to the roadway, I just managed to get it back up and out of the roadway before cars came around the blind mountain turn. The Clutch lever being slightly out of adjustment had no impact on shifting gears, and didn't miss one gear change. Stock clutch lever or Warp9 aftermarket, clutch freeplay 1/16 to 1/4 made no difference. I can not replicate the hazard, it occurred randomly. Technically, weather the neutral light illuminates on the dash or not, in gear, deploying the side stand should kill the bike. Dealer can not duplicate what to we do now?
NHTSA complaint #11582029 — an unverified report by a vehicle owner.
CAM CHAIN ADJUSTER OTHERWISE KNOW AS A DOOHICKEY. IF IT FAILS IT MAY CAUSE THE ENGINE TO SEIZE UP WITHOUT WARNING, I CHANGE MINE AFTER IT BROKE BUT DID NOT CAUSE MASSIVE INTERNAL DAMAGE I WAS UNAWARE THAT MINE HAD FAILED I DID THE CHANGE AS PREVENTATIVE MAINTENANCE THIS PROBLEM HAS BEEN KNOWN TO THE KLR COMMUNITY FOR MANY YEARS BUT KAWASAKI REFUSES TO RECOGNIZE IT, DO A GOOGLE SEARCH ON DOOHICKEY FOR MORE INFO
NHTSA complaint #10926349 — an unverified report by a vehicle owner.
THIS `09 KLR 650 WAS PURCHASED USED FROM GUY WHO BOUGHT IT NEW HAVING APPROX. 8000 MI. MY BIGGEST COMPLAINT IS POSSIBLY DUE TO ENGINE MOUNTING AND VIBRATION WHEREAS FOUND EXHAUST MANIFOLD CLAMP HAD VIBRATED LOOSE AND DETACHED FROM ENGINE EXHAUST PORT. ANOTHER TIME FOUND ONE OF THE SIDE FRAME BOLTS HAD SHEERED OR OTHERWISE BROKE DUE VIBRATION OR DEFECTIVE MATERIAL. OTHER SIMILAR PROBLEMS INVOLVED HAVING TO REPLACE OR FIX SPEEDO CABLE AND THE PROTECTIVE LEG / HEAT EXHAUST SHIELD DUE TO MATERIAL OR VIBRATION ISSUES.
NHTSA complaint #10811996 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2009 KAWASAKI KLR650. THE CONTACT STATED THAT WHILE DRIVING AT 30 MPH, THE MOTORCYCLE STALLED WITHOUT WARNING. THE FAILURE OCCURRED ON MULTIPLE OCCASIONS. THE MOTORCYCLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE WIRING HARNESS NEEDED TO BE REPLACED. THE MOTORCYCLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 3,000.
NHTSA complaint #10667231 — an unverified report by a vehicle owner.
THIS COMPLAINT DOES NOT REPRESENT AN INCIDENT WITH MY PERSONAL VEHICLE. THE KAWASAKI KLR650 SERIES, ALL MODELS SPANNING ALL MFG YEARS, SUFFER FROM A WEAK CHAIN TENSIONER ASSEMBLY FOR THE COUNTERBALANCE SHAFTS. THIS IS AN INTERNAL ENGINE COMPONENT. ON THE INTERNET, THIS ASSEMBLY IS REFERRED TO AS THE "DOOHICKEY." SEARCHING THE WEB FOR "KLR DOOHICKEY" WILL YIELD LITERALLY THOUSANDS OF RESULTS OF BOTH FIXES AND FAILURES. KAWASAKI HAS NEVER CORRECTED THE ISSUE, AND AN INDUSTRY HAS EVEN EMERGED WITH AFTERMARKET PARTS TO CORRECT THE DEFECT THAT THE MANUFACTURER HAS FAILED TO ADDRESS. THIS IS A SERIOUS SAFETY DEFECT WITH THE VEHICLE, AS FAILURE OF THE ASSEMBLY HAS SENT METAL FRAGMENTS THROUGH THE ENGINE AND HAS POTENTIAL TO RAPIDLY SEIZE THE ENGINE. WHEN TRAVELING AT SPEED, THIS CAN CAUSE SUDDEN LOSS OF POWER, OR EVEN AN UNEXPECTED REAR WHEEL LOCKUP ON THE MOTORCYCLE, EITHER OF WHICH CAN BE DEADLY. THERE ARE TENS OF THOUSANDS OF THESE MOTORCYCLES ON THE ROAD, YET ONLY THE ENTHUSIAST COMMUNITY IS AWARE OF THE ISSUE, AND I FEAR THERE ARE MANY OWNERS WHO ARE UNAWARE OF THE RISKS. I WOULD LIKE NHTSA TO INVESTIGATE FOR POTENTIAL RECALL. THANK YOU FOR YOUR TIME.
NHTSA complaint #10628440 — an unverified report by a vehicle owner.
THE TORSION SPRING ON MY KLR 650 FAILED. THIS IS A MAJOR PROBLEM AND HAPPENS TO ALOT OF KLR 650 OWNERS. LUCKY FOR ME IT DIDN'T CAUSE THE ENGINE TO SEIZE WHILE I WAS RIDING.
NHTSA complaint #10562606 — an unverified report by a vehicle owner.
I JUST WISHED TO REPORT SOMETHING I FOUND OUT BY CHANCE, UPON INSPECTING THE INSIDE OF MY ENGINE, AND WHICH COULD HAVE POTENTIALLY CAUSE MY ENGINE TO STOP FUNCTIONING/SEIZE AT SPEED, WHICH IN TURN WOULD HAVE LED ME TO CRASH. THE IDLER SHAFT LEVER & SPRING IN MY ENGINE WAS DEFECTIVE. UPON FINDING THE BROKEN PART I WENT "FISHING" FOR THE MISSING PIECES ON THE BOTTOM OF MY ENGINE USING A MAGNET, AND FOUND ANOTHER BROKEN SPRING! MY TAKE IS THAT THE DEALERSHIP HAD REPLACED THE BROKEN SPRING ONCE ALREADY.. WHICH IS WHY I BELIEVE THERE IS DEFECT ISSUE WITH THIS PART THAT SHOULD BE ADDRESSED. NOTE THAT THE BROKEN PART MOVING FREELY INSIDE MY ENGINE COULD HAVE EASILY CAUSE DAMAGE GETTING TANGLED SOMEWHERE, FOR EXAMPLE IN MY TRANSMISSION GEARS.. THIS COULD EASILY HAVE BEEN A HORROR STORY. HERE ARE PICS I TOOK OF MY ACTUAL BROKEN PARTS AS THEY WERE IN THE ENGINE, AND AFTER REMOVAL (WITH THE ADDITIONAL BROKEN SPRING I FOUND..): PIC 1: HTTP://I97.PHOTOBUCKET.COM/ALBUMS/L229/KATONER/2012-12-05_14-31-39_774.JPG PIC 2: HTTP://I97.PHOTOBUCKET.COM/ALBUMS/L229/KATONER/2012-12-05_18-38-36_487.JPG THANK YOU FOR YOUR ATTENTION AND I HOPE THIS CAN HELP OTHERS. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
NHTSA complaint #10487513 — an unverified report by a vehicle owner.
THE ENGINE BURNS OIL EXCESSIVELY AT HIGHWAY SPEEDS (60 TO 70 MPH). AN ENGINE LOCKUP DUE TO LACK OF LUBRICANT IS A VERY REAL CONCERN DUE TO THE OIL CONSUMPTION RATE.
NHTSA complaint #10462108 — an unverified report by a vehicle owner.
THE IDLER SHAFT LEVER (AKA "DOOHICKEY") BROKE IN HALF AND THE PIECES OF IT WERE FLOATING AROUND IN THE CRANK CASED. THIS IS VERY DANGEROUS BECAUSE IF A PIECE OF THE IDLER SHAFT LEVER GETS CAUGHT IN THE COUNTERBALANCE CHAIN OR CAUSES A CRANK BEARING FAILURE THE ENGINE COULD LOCK UP AT SPEED CAUSING A CRASH. I REPLACED THE IDLER SHAFT LEVER WITH A STRONGER AFTERMARKET COMPONENT.
NHTSA complaint #10454281 — an unverified report by a vehicle owner.
THE STARTER IDLER GEAR SHAFT HOLE/SLEEVE IS BORE/MILLED TO DEEP ON THE OUTSIDE CASING. THE SHAFT MOVES TO THE CASING SIDE AND LOSES CONTACT WITH THE INSIDE BUSHING/SLEEVE, WICH FORMS A GAP AT THE MAIN HOUSING SIDE. THERE IS NOW ENOUGH SPACE FOR THE SPACER WASHER TO FALL INTO THE BOTTOM-END AND CAUSE HUGE/CATASTROPHIC FAILURE.
NHTSA complaint #10434053 — an unverified report by a vehicle owner.
THE 1986-2007 KAWASAKI KLR650 MOTORCYCLE'S TENSIONING SYSTEM FOR THE ENGINE BALANCER SHAFT DRIVE CHAIN IS UNRELIABLE, AND A FAILURE COULD LEAD TO SUDDEN ENGINE LOCK-UP AND LOSS OF VEHICLE CONTROL, POTENTIALLY RESULTING IN INJURY OR FATALITY. THE MOST TROUBLESOME PARTS OF THE BALANCER DRIVE ADJUSTING SYSTEM ARE THE IDLER SHAFT LEVER, P/N 13168-1436 AND THE SPRING, 92144-1860. THE BALANCER ADJUSTER IDLER RIDES ON AN ECCENTRIC SHAFT P/N 39115-1077, AND WHEN THE SHAFT ROTATES IT CHANGES HOW THE TENSION IDLER RELATES TO THE BALANCER CHAIN, ALLOWING THE CHAIN TO BE TENSIONED. THE RECOMMENDED PROCEDURE FOR ADJUSTMENT IS FOR THE USER TO LOOSEN A SCREW THAT HOLDS THE IDLER SHAFT LEVER, ALLOW THE SPRING TO PULL THE IDLER INTO ITS NEW POSITION, AND THEN RETIGHTEN THE SCREW. IF THE IDLER SHAFT LEVER FAILS THE SPRING IS INADEQUATE TO WITHSTAND THE CYCLIC LOADING AS THE CHAIN RUNS AT ENGINE SPEED, AND WILL LEAD TO FAILURE OF THE SPRING AND LOSS OF TENSION IN THE CHAIN. IF THE SPRING FAILS BETWEEN SERVICE INTERVALS BUT THE SYSTEM WAS PROPERLY TENSIONED TO BEGIN WITH, THE CHAIN WILL LOSE TENSION WHEN THE USER LOOSENS THE ADJUSTING SCREW. ALSO ON HIGHER MILEAGE VEHICLES THE SPRING CAN COME OFF ITS ATTACHING POINTS AS IT BECOMES TOO LONG FOR THE APPLICATION, CAUSING IT TO FALL INTO THE ENGINE. IN EITHER CASE THE FAILURE CAN RESULT IN THE BALANCER DRIVE CHAIN BECOMING EFFECTIVELY UNTENSIONED. THE CHAIN IS FREE TO COME OFF ITS SPROCKETS, OR TO BUNCH UP AROUND THE CRANKSHAFT SPROCKET THAT DRIVES IT, OR TO SOMETIMES CATCH ON THE DRIVE SPROCKET AND SOMETIMES SLIP LEADING TO RAPID SPROCKET AND CHAIN WEAR CREATING METAL DEBRIS INSIDE THE ENGINE. IF THE CHAIN BECOMES BUNCHED UP AROUND THE CRANKSHAFT SPROCKET IT COULD LOCK UP THE ENGINE AND MAKE THE VEHICLE SUDDENLY IMMOBILE AND UNCONTROLLABLE.
NHTSA complaint #10399440 — an unverified report by a vehicle owner.
KLR650 ENGINE IDLE LEVER ADJUSTER SPRING FAILED SENDING METAL FRAGMENTS THROUGH OUT THE ENGINE THAT I HAD TO FISH OUT - VERY VERY COMMON PROBLEM TO THE POINT THAT IT IS THE FIRST THING PEOPLE DO WHEN THEY BUY A KLR OF ANY YEAR.
NHTSA complaint #10358886 — an unverified report by a vehicle owner.
TL*THE CONTACT OWNS A 2008 KAWASAKI KLR650. WHILE TRAVELING 65 MPH THE CONTACT NOTICED THAT THE VEHICLE HAD SUDDENLY SHUT OFF WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS INFORMED THAT THE ENGINE NEEDED TO BE REPLACED DUE TO OIL LEAKS. THE VEHICLE WAS NOT REPAIRED AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 5400.
NHTSA complaint #10349235 — an unverified report by a vehicle owner.
2008 KAWASAKI KLR 650 STARTER GEAR COVER IS IMPROPERLY BORED ALLOWING SUPPORT SHAFT TO BECOME UNSUPPORTED ON ONE END. THIS COULD CAUSE THRUST WASHERS TO DROP INTO THE ROTATING FLYWHEEL AT SPEED, LOCKING THE MOTOR AND CAUSING LOSS OF CONTROL. OLDER AND NEWER MODELS BOTH HAVE A RIDGE IN THE OUTER ENGINE COVER THAT PREVENTS THE IDLER GEAR SHAFT FROM DRIFTING OUT TOO FAR AND LOOSING SUPPORT IN THE INNER ENGINE COVER. THIS WAS CLEARLY A MACHINING ERROR. I INSERTED A SMALL SPACER IN THE HOLE TO PREVENT THE SHAFT FROM MOVING.
NHTSA complaint #10334914 — an unverified report by a vehicle owner.
THE SAFETY ISSUE IS ON A 2008 KAWASAKI KLR-650. THE STARTED GEAR IS GRINDING WHEN I TRY TO CRANK THE BIKE. THE DEALER WILL NOT FIX THE ISSUE. THE CAUSE OF THE FAILURE IS A DEEP BORE ON THE SIDE COVER THAT HOLDS THE GEAR. IT IS A MFG ISSUE. MY CONCERN IS WHEN THE GEAR LOCK UP? THERE IS A GOOD CHANCE IT COULD LOCK UP AS I'M RIDING DOWN THE RODE.
NHTSA complaint #10334707 — an unverified report by a vehicle owner.
THE STARTER GEAR SHAFT CAN MIGRATE OUT IN THE LEFT SIDE ENGINE COVER, LEAVING THE GEAR UNSUPPORTED ON THE INBOARD SIDE AND ALLOWING A WASHER TO MIGRATE LOOSE INTO THE ENGINE--POTENTIALLY CAUSING THE TRANSMISSION TO LOCK UP OR THE TIMING CHAIN TO SKIP TEETH AND CAUSE THE INTAKE OR EXHAUST VALVES TO HIT THE PISTON TOP, BENDING VALVES AND MAKING THE ENGINE INOPERABLE.
NHTSA complaint #10334599 — an unverified report by a vehicle owner.
COVER SIDE HOLE THAT LOWER STARTER GEAR PIN RIDES IN IS MILLED TOO DEEP AND CAN RESULT IN SEVERE ENGINE DAMAGE. WHILE INSTALLING A BALANCER TENSION SPRING UPGRADE (ANOTHER ISSUE WITH THESE MOTORCYCLES) I FOUND I HAD THIS ISSUE. I HAD TO INSTALL A SPACER TO FIX AND PREVENT THE OTHER SIDE FROM COMING OUT OF ENGINE SIDE HOLE AND CAUSING DAMAGE.
NHTSA complaint #10334646 — an unverified report by a vehicle owner.