AI DamageKawasaki KL650E: problems, complaints, bulletins
Summary for the Kawasaki KL650E across 4 model years: 20 owner complaints and 0 NHTSA service bulletins, plus repair videos. Pick a year for details.
Model years
What fails most often
- 1 Exterior lighting 35% of all complaints
- 2 Electrical system 25% of all complaints
- 3 Engine and cooling 25% of all complaints
- 4 Structure 15% of all complaints
- 5 Engine 5% of all complaints
- 6 Powertrain 5% of all complaints
- 7 Visibility 5% of all complaints
- Exterior lighting: 7 complaints (35% of all).
- Electrical system: 5 complaints (25% of all).
- Engine and cooling: 5 complaints (25% of all).
- Structure: 3 complaints (15% of all).
- Engine: 1 complaints (5% of all).
Symptoms owners describe
How many of the 20 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) |
|---|---|---|---|
| Exterior lighting | 7 | 0 | 0 |
| Electrical system | 5 | 0 | 0 |
| Engine and cooling | 5 | 0 | 0 |
| Structure | 3 | 0 | 0 |
| Engine | 1 | 0 | 0 |
| Powertrain | 1 | 0 | 0 |
| Visibility | 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.
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.
While driving approximately 15 mph, the vehicle suddenly stalled without warning. The vehicle was not taken to the dealer for diagnostics. The contact referenced nhtsa campaign id number: 09v062000 (electrical system:wiring) however, was advised by the manufacturer that the vin was not included in the recall.
Tl* the contact owns a 2008 kawasaki kl650e. The contact stated that while driving 30 mph, the vehicle lost all electrical power. The dealer and the manufacturer were notified, but offered no assistance.
The contact attempted to start the vehicle and it failed to start. The contact was eventually able to start the vehicle; however after inspecting the vehicle the contact noticed the metal bracket attached to the generator was extremely sharp and was cutting into the wiring harness.
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.
While traveling at night approximately 55 mph, the engine completely stalled with the loss of the electrical system. The vehicle was towed to an authorized dealer for diagnosis. There was recall related to the defect under nhtsa campaign id number 09v062000 (electrical system: wiring).
When owners complained
NHTSA complaints by filing year. The peak shows at what age the problems show up most.
What to check before buying
- Exterior lighting. Headlamps, leveling, sensors and mounts after a frontal hit.
- Electrical system. Scan all modules, test the battery and alternator, inspect connectors near the impact zone.
- Engine and cooling. Radiator and fan after a frontal hit, coolant level and condition, overheating.
- 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.