AI DamageKawasaki KL650A: problems, complaints, bulletins
Summary for the Kawasaki KL650A across 4 model years: 7 owner complaints and 0 NHTSA service bulletins, plus repair videos. Pick a year for details.
Model years
| Year | Owner complaints | involving a crash | Technical service bulletins (TSB) | YouTube repair videos |
|---|---|---|---|---|
| 2007 | 1 | 0 | 0 | 0 |
| 2006 | 3 | 0 | 0 | 0 |
| 2005 | 2 | 0 | 0 | 0 |
| 2004 | 1 | 0 | 0 | 0 |
What fails most often
- 1 Engine and cooling 57% of all complaints
- 2 Engine 14% of all complaints
- 3 Powertrain 14% of all complaints
- 4 Suspension 14% of all complaints
- Engine and cooling: 4 complaints (57% of all).
- Engine: 1 complaints (14% of all).
- Powertrain: 1 complaints (14% of all).
- Suspension: 1 complaints (14% of all).
Components owners complain about
| Component | Owner complaints | involving a crash | Technical service bulletins (TSB) |
|---|---|---|---|
| Engine and cooling | 4 | 0 | 0 |
| Engine | 1 | 0 | 0 |
| Powertrain | 1 | 0 | 0 |
| Suspension | 1 | 0 | 0 |
What owners report
Short excerpts of NHTSA complaints in the original wording. These are owner statements not verified by NHTSA; personal data removed.
Balancer chain began making noise attempted factory recommended adjustments. Concern was unresolved. Removed stator cover found quadrant and tensioner broken.
On the basis of anecdotal information I replaced the stock balancer chain tensioner on my 2005 kawasaki klr 650 motorcycle. These have been known to have problems in this area, and sure enough the spring that is to tension the balance chain as it wears was broken and inoperative.
The failure was caught in time before catastrophic engine failure could take place. I purchased a balancer lever upgrade kit from eagle manufacturing of california. The cost of this kit was approximately $140.00. I also purchased a motorcycle jack to accomplish the repair.
Preload adjuster broke on 2006 klr 650 second time I attempted to adjust it with less that 10k miles on it.
2006 klr 650 kawasaki motorcycle broken balancer chain lever even though adjusted regularly by kawasaki dealer. Metal fragments in the engine causing potential damage. Incurred significant repair costs to replace the defective part and repair with after market replacement as the kawasaki part is defective.
The balance shaft tenisoner and chain broke on my 2004 klr 650 before I had 10,000 miles on it.
When owners complained
NHTSA complaints by filing year. The peak shows at what age the problems show up most.
What to check before buying
- Engine and cooling. Radiator and fan after a frontal hit, coolant level and condition, overheating.
- Engine. Cold start, unusual noises, oil leaks and engine codes.
- Powertrain. Shift quality under load, harsh shifts, transmission codes, CV joints.
- Suspension. Wheel alignment, control arms, subframe, even tire wear.
Other models of this make
Read also
Sources: public NHTSA data (USA): service bulletins and owner complaints; YouTube: links to videos credited to their authors. Complaints are owner statements not verified by NHTSA, and describe defects rather than crash damage. Data updated 2026-11-05.