AI DamageKawasaki KL650A19: problems, complaints, bulletins
Summary for the Kawasaki KL650A19 across 1 model years: 10 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 |
|---|---|---|---|---|
| 2005 | 10 | 0 | 0 | 0 |
What fails most often
- 1 Engine and cooling 80% of all complaints
- 2 Steering 30% of all complaints
- 3 Structure 10% of all complaints
- Engine and cooling: 8 complaints (80% of all).
- Steering: 3 complaints (30% of all).
- Structure: 1 complaints (10% of all).
Symptoms owners describe
How many of the 10 NHTSA complaints mention each symptom (automatic count from complaint text; one complaint can mention several).
Components owners complain about
| Component | Owner complaints | involving a crash | Technical service bulletins (TSB) |
|---|---|---|---|
| Engine and cooling | 8 | 0 | 0 |
| Steering | 3 | 0 | 0 |
| Structure | 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.
Tl contact owns a 2005 kawasaki klr650 (na). The contact noticed that approximately ten bolts were missing from his vehicle. The foot peg bolts and muffler mounting bolts were missing, which caused the foot peg to detach.
While doing pm on the 2005 kawasaki klr650 I found that the tension idler arm, known in the klr community as the doohickey was and has been broken. While the motorcycle still ran most serioiuly failed.
2005 kawasaki klr 650 8,250 miles. The idler shaft lever (doohickey) retention / return spring was broken. I opened the case to replace this part that has had problems with failure and sure enough mine was broken!
This can lead to catastrophic engine failure as the camshaft chain is no longer being tightened correctly. I then replaced the idler shaft lever and the spring with aftermarket parts.
The balancer chain adjuster spring broke and lodged in the oil screen.
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.
- Steering. Steering play, power assist, rack and tie rods after a wheel impact.
- Structure. Rails, pillars, panel gaps, signs of pulling or welding.
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.