2008 Kawasaki KLR650

Defect. ON CERTAIN MOTORCYCLES, THE SPRING RETAINING PIN ON THE FRAME MAY NOT HAVE BEEN COMPLETELY WELDED IN PLACE AND COULD FALL OUT, ALLOWING THE SIDESTAND TO DROP INTO THE "PARKING" POSITION.

Risk. IF THIS OCCURRED WHILE THE VEHICLE WAS IN MOTION, A CRASH COULD OCCUR.

Remedy. KAWASAKI WILL REPURCHASE THESE MOTORCYCLES. THE RECALL BEGAN ON JUNE 1, 2007. ALL DEALERS/OWNERS HAVE BEEN NOTIFIED.

TURNED IN COMPLAINT ON A FEW DAYS AGO. RECEIVED THIS TRACKING NUMBER 11063172. WHAT'S MY NEXT STEP? THE COMPLAINT WAS TURN SIGNALS FALLING OFF.

TURN SIGNALS FELL OFF. HANGING ON BY ELECTRIC WIRING

EXTERIOR TURN SIGNALS DRYROT,THEREFORE TURN SIGNAL INDICATORS FALLING OFF AND HANGING ON BY WIRE. ONE IN FRONT AND ONE IN BACK. THE ONE IN BACK FELL ON TO MUFFLER MELTING PLASTIC.

TURN SIGNALS HAVE A RUBBER MOUNT THAT FALLS OFF. *TR

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. *TR

TL* THE CONTACT OWNS A 2008 KAWASAKI KLR 650 MOTORCYCLE. THE CONTACT STATED THAT THE TURN SIGNALS RUBBER DETERIORATED AND FELL OFF THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 4,900.

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. *TR

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.

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. *TR

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. *TR

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. *TR

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. *TR

2008 KAWASAKI KLR 650 MOTORCYCLE. CONSUMER STATES SEVERAL PROBLEMS WITH MOTORCYCLE AND HAS RECEIVED RECALLS *TGW SINCE PURCHASING THE MOTORCYCLE, THE CONSUMER HAD TO REPLACE THREE BATTERIES. WHILE CHANGING THE OIL FOR THE FIRST TIME, HE DISCOVERED THE ENGINE WAS CONSUMING EIGHT TO TEN OUNCES OF OIL PER THOUSAND MILES OF USE. THE CONSUMER CONTACTED THE MANUFACTURER AND WAS INFORMED THE OIL CONSUMPTION FELL WITHIN THE ACCEPTABLE RANGE AS SPECIFIED BY KAWASAKI ENGINEERS. THE CONSUMER BELIEVED THE PISTONS WERE TOO SMALL FOR THE CYLINDER BORE ON HIS BIKE. *JB

2008 KAWASAKI KLR 650 ENGINE USES AN ABNORMAL AMOUNT OF OIL, LEADING TO ENGINE SEIZURE/FAILURE/COSTLY DAMAGE. *TR

THE 2008 KAWASAKI KLR 650 MOTORCYCLE OIL DRAIN PLUG SHOULD BE RECALLED AND CHANGED TO A LOW-PROFILE DRAIN PLUG. WITH ITS CURRENT HEIGHT, IT PROTRUDES BELOW THE SKID PLATE AND IS PRONE TO DAMAGE. ADDITIONALLY THE SKID PLATE IS MADE OF FLIMSY PLASTIC AND DOES NOT PROVIDE ADEQUATE PROTECTION FOR THE ENGINE. WHILE TRAIL RIDING THIS NEW DUAL-SPORT MOTORCYCLE WITH ONLY 1400 MILES ON IT, I RODE OVER A SMALL ROCK, THIS CRACKED THE FLIMSY SKID-PLATE/ENGINE GUARD AND LOOSENED THE OIL DRAIN PLUG. WHILE RIDING HOME LATER ON THE FREEWAY, THE DRAIN PLUG FELL OUT, ALL THE OIL EVACUATED QUICKLY AND THE MOTOR SEIZED. THIS MOTORCYCLE IS STILL UNDER WARRANTY BUT THE DEALER INSISTED THAT THIS REPAIR WOULD NOT BE COVERED. THE PISTON RINGS WERE SEIZED AND THE REPAIR INVOLVES BORING THE CYLINDER, GETTING A LARGER PISTON AND RINGS, PLUS GASKETS AND LABOR. THE ESTIMATE FOR THIS REPAIR WAS $636.00. THE EVIDENCE OF THE NEED FOR THESE CHANGES TO THE MOTORCYCLE ARE THE PREVALENCE OF THESE PARTS AS AFTERMARKET ACCESSORIES, TO FILL THE OBVIOUS DEFICIENCY. THE LOW PROFILE DRAIN PLUGS ARE ROUGHLY $12.00 AND THE MORE STURDY ENGINE GUARDS ARE AROUND $120.00. *TR

ALL RUBBER GROMMETS AND PROTECTIVE BOOTS ARE DRY ROTTING AT AN ACCELERATED RATE BROUGHT PROBLEM TO DEALERS ATTENTIONS AND HE IS WILLING TO REPLACE ALL THE PARTS AS LONG AS I PAY FOR THEM. *TR

TL*THE CONTACT OWNS A 2008 KAWASAKI KLR650. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN ID NUMBER 09V059000 (ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE) AND IMMEDIATELY CALLED THE DEALER. THE DEALER STATED THAT THE VEHICLE SHOULD NOT BE DRIVEN BECAUSE THE BOLTS COULD LOOSEN COMPLETELY AND THE MUFFLER COULD POSSIBLY SEPARATE FROM THE VEHICLE, CAUSING A CRASH OR SERIOUS INJURY. THE DEALER ALSO STATED THAT THEY WOULD NOT PAY FOR TOWING. THE CONTACT DOES NOT WANT TO HAVE THE VEHICLE REPAIRED IF HE HAS TO PAY FOR TOWING. THE VEHICLE HAS NOT YET BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 2,500.

THE CONDITIONS HEREIN MAY CAUSE AN ENGINE FAILURE. THIS FAILURE COULD CAUSE THE ENGINE TO SEIZE WHICH COULD CAUSE THE LOSS OF CONTROL OF THE VEHICLE [MOTORCYCLE]. THE VEHICLE WAS IN USE UNDER NORMAL "STREET" CONDITIONS. HIGH OIL CONSUMPTION DUE TO MANUFACTURING DEFECT/ WORKMANSHIP. 1 QUART+ OF OIL PER 300 MILES, RESULTING IN HIGH AIR POLLUTION & POSSIBLE ENGINE SEIZURE---FROM THE LOSS OF OIL! PISTON RINGS LEAK OIL. THERE IS ALSO A GROOVE IN ENGINE'S CYLINDER WALL [3"L X 5/32"W X 1/64"D] DUE TO IMPROPER PART ASSEMBLY [PISTON'S WRIST PIN CLIP; A FACTORY DEFECT]. THE ENGINE'S EXHAUST VALVES LEAK WHICH ALSO PRODUCES POOR AIR QUALITY CONTROL. THESE CONDITIONS ARE INTERNAL TO THE ENGINE AND WERE CREATED DURING THE MANUFACTURING PROCESS. THESE FAILURES CAN ONLY BE DETERMINED THROUGH THE DISASSEMBLY OF THE ENGINE. THE ABOVE VEHICLE'S HAS ONLY BEEN USED FOR 2,085 [2K] MILES. IT IS A 2008 MODEL YEAR. THE ABOVE ENGINE FAILS TO MEET AIR QUALITY STANDARDS. THE COST OF REPAIR IS BEING ESTIMATED BETWEEN $800-1000. THIS ENCOMPASSES PARTIAL VEHICLE DISASSEMBLE, UPPER ENGINE DISASSEMBLE, MACHINE SHOP WORK, REPLACEMENT PARTS, ENGINE REASSEMBLE, AND THE REASSEMBLE OF THE AREA AROUND THE ENGINE [IT'S A MOTORCYCLE]. TO CORRECT THE ABOVE FAILURES NEW PARTS MUST BE INSTALLED ALONG WITH NECESSARY MACHINING OF ENGINE'S CYLINDER. *TR

RIDING 2008 KAWASAKI KLR-650 AT SPEED LESS THAN 60MPH. AFTER RIDE (2) BLINKERS, ONE FRONT & ONE REAR FELL OFF. THE RUBBER MOUNTING STALK ON EACH BLINKER BROKE AT THE BASE AND THE TURN SIGNALS FELL OFF ONLY TO BE HELD ON BY THE WIRES. *TR

WHILE TRAVELING ON MAIN HIGHWAY AT 2AM ENROUTE TO WORK I LOST ENGINE AND LIGHTS. NO WARNING. UNABLE TO SEE ANYTHING LET ALONE OTHER MOTORISTS BEING ABLE TO SEE ME. REPLACED MAIN FUSE & BATTERY...NOT THE PROBLEM. TAKING BIKE TO DEALER TODAY. OUT OF WARRANTY BY APPROXIMATELY ONE MONTH. ONLY 1500 MILES ON BIKE. DEALER CLAIMS ELECTRICAL SHORTAGE SOMEWHERE??? COULD HAVE BEEN SERIOUSLY INJURED OR KILLED. *TR

TRAVELING TO WORK. TURN SIGNAL FELL OFF FOR NO REASON. MELTED TO EXHAUST PIPE. DEALER INFORMED ME THAT KAWASAKI IS AWARE OF THE PROBLEM BUT HAS NOT ISSUED A RECALL. *TR

ALL 4 OF MY TURN SIGNALS HAVE FAILED. THE RUBBER BOOT THAT HOLDS THE TURN SIGNALS ON HAVE ALL FAILED, LEADING TO DANGLING TURN SIGNALS. *TR

ALL FOUR TURN SIGNALS FELL OFF IN THE FIRST YEAR OF OWNERSHIP. *TR

I RIDE MY BIKE EVERY DAY TO WORK. IT IS GARAGED AND WHEN OUTSIDE IT IS ALWAYS COVERED. I HAVE NEVER TAKEN THE BIKE OFF ROAD OR DIRT TRAIL RIDING. THE BIKE HAS NEVER FALLEN, BEEN DROPPED OR KNOCKED OVER. WHEN I PULLED THE COVER OFF ON 9/20/2008 AT 1957HRS TO HEAD HOME I FOUND THAT THE LEFT FRONT TURN SIGNAL WAS SNAPPED OFF AT THE FARING. *TR

FRONT AND REAR TURN SIGNALS FALL OFF. THEY ARE DESIGNED TO FALL OFF WHEN STRUCK BY ANOTHER OBJECT, BUT IN REALITY, THEY FALL OFF DURING NORMAL USE OF THE VEHICLE. THE TURN SIGNALS DO NOT HAVE TO TOUCH ANYTHING TO FALL OFF. WHEN THEY FALL OFF THEY ARE HANGING BY A WIRE AND FLOP AROUND. AT THIS POINT, YOUR TURN SIGNALS ARE USELESS. THIS HAS HAPPENED 6 TIMES IN ONE YEAR. I WAS OFFERED NO ASSISTANCE OR ACKNOWLEDGEMENT OF THE PROBLEM BY THE DEALER EVEN DURING THE WARRANTY PERIOD, SO I REPLACE THE TURN SIGNAL AND WAIT FOR IT TO HAPPEN AGAIN. I HAVE TALKED TO OTHER OWNERS AND THEY ARE HAVING THE SAME PROBLEM. *TR

TURN SIGNAL INDICATORS SUFFERING RUBBER ROT DAMAGE CAUSING STALK TO SNAP. THIRD INSTANCE ON SAME MOTORCYCLE. PARKED INSIDE AT HOME AND AT WORK. *TR

I HAVE HAD A FRONT AND REAR BLINKER TO BREAK, THE RUBBER PART, RIGHT IN THE MIDDLE. NO CRASH WAS INVOLVED. COULD HAVE BEEN SOMEONE BRUSHED AGAINST MY MOTORCYCLE,BUT NOT THAT I KNOW OF. *TR

RIGHT TURN SIGNAL ON 2008 KAWASAKI KLR 650 BREAK IN TWO. *TR

2 OF 4 TURN INDICATORS ON THE MOTORCYCLE HAVE FALLEN OFF; THE INDICATOR STALKS APPEAR FAULTY - RUBBER PEELS APART OR FALLS OFF LEAVING INDICATORS HANGING BY WIRES. *TR

I HAVE A 2008 KAWASAKI KLR 650 DUAL PURPOSE MOTORCYCLE WITH LESS THAN 1500 MILES THAT IS KEPT IN A CLIMATE CONTROLLED GARAGE. A FEW MONTHS AGO, I NOTICED THAT THE RIGHT REAR TURN SIGNAL WAS HANGING BY THE WIRE POWERING IT, AND THAT THE RUBBER STEM WHICH MOUNTS THE TURN SIGNAL WAS TORN. I ASSUMED AT THAT TIME THAT A FAMILY MEMBER HAD ACCIDENTALLY BUMPED IT AND KNOCKED IT OFF. I REMOVED IT COMPLETELY TO KEEP IT FROM CAUSING FURTHER DAMAGE AND NOTICED THAT THE RUBBER WAS VERY DELICATE AND TORE EASILY. YESTERDAY, 9-12-08, I FOUND THAT ALSO WHILE PARKED, THE LEFT FRONT TURN SIGNAL HAD FALLEN OFF. UPON INSPECTION, I FOUND THE REMAINING TURN SIGNALS TO BE FOLLOWING SUIT. ALL OF THIS HAS OCCURRED ON A MOTORCYCLE THAT IS RIDDEN INFREQUENTLY AND STORED INSIDE. *TR

TL*THE CONTACT OWNS A 2008 KAWASAKI KLR650. THE CONTACT STATED THAT THREE OF THE FOUR TURN SIGNAL LIGHTS DETACHED FROM THE VEHICLE WITHOUT WARNING. ALSO, THE RUBBER THAT ENCASES THE WIRES IS DRY ROTTED AND BRITTLE. THE DEALER AND MANUFACTURER WERE NOTIFIED. THE CURRENT MILEAGE WAS 1,200 AND FAILURE MILEAGE WAS 800. UPDATED 10/01/08 *BF UPATED 10/06/08. *JB

2008 KAWASAKI KLR 650 RIGHT REAR TURN SIGNAL RUBBER BETWEEN THE SIGNAL AND FAIRING FALLING APART. REPAIRED WITH DUCT TAPE. *TR

REAR TURN SIGNALS FELL OFF WHILE JUST RIDING DOWN THE ROAD. *TR

TURN SIGNALS "FALL OFF" 2008 KAWASAKI KLR 650 AFTER ABOUT 2000 MILE OF NORMAL USE. RUBBER MOUNT TEARS AND ALLOWS TURN SIGNAL TO HANG FROM WIRES. DID A GOOGLE SEARCH "08 KLR BROKEN TURN SIGNAL" AND FOUND THAT IT IS A RE-OCCURRING PROBLEM. COULD CAUSE AND ACCIDENT, OR ELECTRICAL FAILURE. *TR

BOTH REAR TURN SIGNALS FELL OFF. THE RUBBER MOUNTS BROKE, THE LIGHTS ARE HANGING BY THE WIRES. *TR

TURN SIGNALS FALL OFF. *TR

ALL FOUR TURN SIGNALS, FRONT AND REAR HAVE FALLEN OFF AT 3,500 MILES. THE RUBBER JUST DISINTEGRATES IN YOUR HAND. *TR

TURN SIGNAL FELL OFF ON MOTORCYCLE(2008 KAWASAKI KLR 650). *TR

TURN SIGNALS ON 2008 KLR 650 FALLING OFF. *TR

EXTERIOR LIGHTING (BLINKERS) FELL OFF. *TR

SHORTED WIRING HARNESS UNDER GAS TANK RESULTING IN FAILURE OF 20 AMP MAIN FUSE. *TR

ALL RUBBER GROMMETS AND PROTECTIVE BOOTS ARE DRY ROTTING AT AN ACCELERATED RATE. *TR

NEW 2008 KAWASAKI KLR 650. BUILD DATE OF 05/07. TURN SIGNALS FALL OFF DUE TO CRUMBLING RUBBER MOUNTS. OTHER RUBBER GROMMETS AND BOOTS ARE ALSO DISINTEGRATING. *TR

TURN SIGNAL BROKE OFF. *TR

I HAVE BEEN DRIVING MY 2008 KAWASAKI KLR 650 ON BACK ROAD AND HIGHWAYS FOR ABOUT 6 MTHS AND 3000 MILE. YESTERDAY I FIND MY RIGHT FRONT BLINKER HANGING FROM THE WIRES. THE RUBBER THAT HOLDS THE LIGHT JUST TORE. MY DEALER TELLS ME THAT IT ISN'T COVERED BY AND I HAVE TO PAY $40 FOR A NEW STOCK LIGHT. I FEEL THAT THIS IS DEFECT IN THE MATERIAL THE LIGHT SUPPORT IS MADE OF. *TR

TURN SIGNALS BROKE AND FELL OFF. *TR

BOTH REAR TURN SIGNALS FELL OFF WITHOUT MY KNOWLEDGE WHILE RIDING ON STATE HIGHWAYS ON MY KAWASAKI 2008 KLR 650 MOTORCYCLE WITH 1200 MILES ON IT. THIS IS A KNOWN DEFECT IN THE RUBBER PART THAT ACTS AS A SPRING CONNECTOR FROM FRAME TO LIGHT. FOLLOWING MOTORISTS WERE UNABLE TO DETERMINE MY INTENTIONS. SIMILAR COMPLAINTS CAN BE SEEN AT HTTP://KLRWORLD.COM/FORUMS/INDEX.PHP?TOPIC=9409.MSG109460. KAWASAKI SHOULD BE FORCED TO RECALL AND REPAIR ALL 2008 KLR 650 MODELS BEFORE SOMEONE IS KILLED BECAUSE OF THEIR POOR PART DESIGN. THANK YOU, ROBERT BROWN *TR

I HAVE A BROKEN PRE-LOAD ADJUSTER ON REAR SHOCK OF 2008 KAWASAKI KLR 650 MOTORCYCLE. THE OWNERS MANUAL DIRECTIONS WERE FOLLOWED EXACTLY. THIS IS NOT AN ISOLATED CASE AS THERE ARE MANY SIMILAR OCCURRENCES ON THE IDENTICAL MOTORCYCLE. A RECALL MUST BE ISSUED. *TR

TURN SIGNAL JUST BROKE OFF. IT APPEARS THAT IT HAS NO SUPPORT OTHER THAN A RUBBER BASE. *TR

I HAD ONLY HAD MY MOTORCYCLE KLR 650 2008, AND FOUND REAR RIGHT LIGHT BROKEN OFF. A WEEK LATER FOUND LEFT REAR LIGHT BROKEN OFF. A MONTH LATER I FOUND THE FRONT RIGHT BROKEN OFF, AND SOON AFTER THE FRONT LEFT WAS FOUND BROKEN AS WELL. PLEASE KEEP IN MIND THAT THERE WERE NO ACCIDENTS. *TR