2003 KAWASAKI KLR650 Problems & Recalls

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. *TR

Mileage: 15,000

KAWASAKI KLR 650 MOTORCYCLE CHAIN TENSIONER COUNTER BALANCER AND RETAINER SPRING BROKEN AND MISSING. THE BROKEN PIECES CAN CAUSE CATASTROPHIC FAILURE INCLUDING ENGINE SEIZURE WHILE IN OPERATION. REPLACED THE PARTS FROM AFTERMARKET SUPPLIER. *TR

Mileage: 25,600

I HAVE A 2003 KAWASAKI KLR650 AND THE BALANCER LEVER ADJUSTER IS BROKEN. IT MAKES A LOUD NOISE AND THERE IS A POSSIBILITY OF ENGINE SEIZURE. I HAVE DONE NOTHING TO FIX THIS YET AND AM DRIVING AN ALTERNATE VEHICLE. *JB

Mileage: 2,200

I JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKE...

Mileage: 8,900

I JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKE...

Mileage: 8,900

WHEN THE MOTORCYCLE WAS TAKEN OUT OF STORAGE CONSUMER NOTICED THAT TIRES SIDEWALL DEVELOPED WEATHER CHECKS. THESE WERE SMALL CRACKS THAT WENT AROUND THE SIDEWALL OF THE TIRES. THE MOTORCYCLE WAS DRIVEN FOR 6 MONTHS, THEN STORED FOR 6 MONTHS PRIOR TO THIS PROBLEM OCCURRING. DEALERSHIP WAS CONTACT...

THE MOTORCYCLE CAM CHAIN ADJUSTER SPRING BROKE AND CAUSED THE VEHICLE TO STALL WHILE DRIVING. SAUSAGE, KLR 650, 2003. *AK WHILE DRIVING CONSUMER HEARD A GRINDING SOUND FROM THE LEFT SIDE OF THE ENGINE. THE BROKEN SPRING BENT THE INTAKE VALVE AND DAMAGED VALVE GUIDES (SAUSAGE 630 2003). *TS ...

Mileage: 10,265