Kawasaki is recalling 16,167 my 2008-2009 klr 650 (kl650e8f/l, kl650e9f/l) motorcycles. The muffler assembly is secured to the frame of the motorcycle by two bolts. It is possible that heat expansion cycles of the muffler, combined with vibration from...
Engine & cooling
Kawasaki KL650E Engine problems by year
6 complaints filed with NHTSA about the Kawasaki KL650E's engine & cooling. Stalling, loss of power, oil consumption, overheating, head gaskets, timing chains and engine failure.
Engine complaints by model year
Engine recalls
On certain motorcycles, insufficient tightening of the muffler mounting bolts could allow the bolts to loosen.
Latest KL650E engine complaints
The balancer idle level spring broke and sent metal through the engine. After doing some reading I guess this is a common fail for all klr650s the aftermarket world came up with an upgrade to fix the flaw. The call it the doohickey repair. Why is kawasaki not taking care of the problem.
2009 Klr 650 with only 7k miles, engine cut off suddenly at highway speed. Mechanics reporting the entire engine will need to be replaced due to excessive oil usage causing damage in all parts of engine. *Kb
New 09 kawasaki klr650 bought from ridersville cycle in berkeley springs, wv. On initial ride oil drain plug came out, draining oil, leading to engine seizing while traveling at 55mph, but for the quick reactions of the rider, a serious accident would have pursued. Dealer/manufacturer error for not checking bolt tightness, as 2 quarts of oil had to be added to bike upon pickup, indicating the bolt was already loose and oil had leaked out, as the bikes are delivered full according to kawasaki. Oil capacity of bike...
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is 2.6 Qts. Or manufacture defect in design of bike, by not building it with a skid plate that protects the bolt and bottom of crankcase from impact. Something they readily admit by selling an accessory skid plate that covers the bolt, but with no mention or warning that it should be added to the bike. *Tr
Tl*the contact owns a 2008 kawasaki kl650e motorcycle. The contact received a recall notice for nhtsa campaign id number 09v059000 (engine and engine cooling:exhaust system:manifold/header/muffler/tail pipe) and called the dealer to have the vehicle repaired. He was informed by a technician that the repair consisted of removing the paint from the muffler mount tabs and replacing the mount bolts, nut, and washer. As a professional technician himself, the contact was concerned that the removal of the paint would inevitably lead to rust failures. The vehicle has not yet been repaired according to the recall. The manufacturer did not assist. The failure and current mileages were 4,584.
Tl*the contact owns a 2008 kawasaki versys kl650e. While driving 40 mph or more, the wind pushes the left and right exterior mirrors (specifically the right mirror) towards him. The contact cannot see anyone in the rear. He attempted to adjust the mirror while driving, but nearly crashed. The vehicle also made a popping sound when the gears were switched. He was initially informed that a chain was loose. The dealer tightened the chain, but the failure still persists. When the vehicle was taken back to the...
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dealer, they stated that the failure was normal. On the second trip to the dealer, the contact was informed that he would be responsible for repairing the mirrors. The current mileage was 1,000 and the failure mileage was 0. Updated 5/20/08 *cn the consumer stated when the motorcycle is hot, smoke emits from the engine.
Idler shaft spring broken causing broken piece to fall into engine could cause locking up of engine causing a crash. *Tr
Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked daily. Complaints are owners' own reports and are not verified. How we use the data