Model year record

2008 Kawasaki KL650E recalls & problems

The 2008 Kawasaki KL650E has 3 safety recalls and 12 owner complaints on file with NHTSA. The most-reported problem area is exterior lighting (7 complaints).

Recalls3safety recalls

Complaints12filed by owners

Crashes · fires0 · 0reported in complaints

Injuries · deaths0 · 0reported in complaints

Safety recalls

Electrical systemFeb 20, 2009

Wiring

Recall 09V06200016,167 vehicles

Problem: KAWASAKI IS RECALLING 16,167 MY 2008-2009 KLR 650 (KL650E8F/L, KL650E9F/L) MOTORCYCLES. WIRES IN THE WIRING HARNESS MIGHT BE DAMAGED DUE TO RUBBING CONTACT WITH A PORTION OF THE MOTORCYCLE FRAME.
Risk: THIS COULD RESULT IN LOSS OF ELECTRICAL POWER TO THE ENGINE CREATING A RISK OF A CRASH RESULTING IN INJURY OR DEATH.
Fix: DEALERS WILL INSPECT AND IF NECESSARY REPLACE THE MAIN WIRING HARNESS FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 24, 2009. OWNERS MAY CONTACT KAWASAKI AT 866-802-9381.

Engine and engine coolingFeb 19, 2009

Exhaust system › Manifold/header/muffler/tail pipe

Recall 09V05900016,167 vehicles

Problem: KAWASAKI IS RECALLING 16,167 MY 2008-2009 KLR 650 (KL650E8F/L, KL650E9F/L) MOTORCYCLES. THE MUFFLER ASSEMBLY IS SECURED TO THE FRAME OF THE MOTORCYCLE BY TWO BOLTS. IT IS POSSIBLE THAT HEAT EXPANSION CYCLES OF THE MUFFLER, COMBINED WITH VIBRATION FROM VEHICLE OPERATION MAY CAUSE LOOSENING OF THE MUFFLER MOUNTING BOLTS.
Risk: IF THE BOLTS LOOSEN COMPLETELY, IT IS POSSIBLE FOR THE MUFFLER TO SEPARATE FROM THE MOTORCYCLE, CREATING A RISK OF A CRASH RESULTING IN INJURY OR DEATH.
Fix: DEALERS WILL REMOVE THE PAINT FROM THE MUFFLER MOUNT TABS AND REPLACE THE MOUNT BOLTS, NUT, AND WASHER FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 23, 2009. OWNERS MAY CONTACT KAWASAKI AT 866-802-9381.

Engine and engine coolingOct 16, 2007

Exhaust system › Manifold/header/muffler/tail pipe

Recall 07V48600033,693 vehicles

Problem: ON CERTAIN MOTORCYCLES, INSUFFICIENT TIGHTENING OF THE MUFFLER MOUNTING BOLTS COULD ALLOW THE BOLTS TO LOOSEN.
Risk: IF THE BOLTS LOOSEN COMPLETELY, IT IS POSSIBLE FOR THE MUFFLER TO SEPARATE FROM THE MOTORCYCLE AND CREATE THE POTENTIAL FOR A CRASH.
Fix: DEALERS WILL TIGHTEN TWO MUFFLER MOUNTING BOLTS TO THE PROPER TORQUE FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 22, 2007. OWNERS MAY CONTACT KAWASAKI AT 1-866-802-9381.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

What owners report

Problem area	Complaints	Typical mileage*
Exterior lightingTurn signal	7	1,500 mi
Engine and engine coolingExhaust system	2	—
StructureBody	2	—
VisibilityRearview mirrors/devices › Exterior	1	—
Power trainManual transmission	1	—
Electrical system	1	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Electrical system
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 WAS INFORMED OF THE RECALL UNDER NHTSA CAMPAIGN ID NUMBER: 09V062000 (ELECTRICAL SYSTEM:WIRING) AND STATED THAT HE EXPERIENCED EVERYTHING THE RECALL LISTED. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 11,700.
Jul 10, 2012 · 11,700 miles
Engine and engine cooling › Exhaust system
TL*THE CONTACT OWNS A 2008 KAWASAKI KL650E MOTORCYCLE. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN ID NUMBER 09V059000 (ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE) AND CALLED THE DEALER TO HAVE THE VEHICLE REPAIRED. HE WAS INFORMED BY A TECHNICIAN THAT THE REPAIR CONSISTED OF REMOVING THE PAINT FROM THE MUFFLER MOUNT TABS AND REPLACING THE MOUNT BOLTS, NUT, AND WASHER. AS A PROFESSIONAL TECHNICIAN HIMSELF, THE CONTACT WAS CONCERNED THAT THE REMOVAL OF THE PAINT WOULD INEVITABLY LEAD TO RUST FAILURES. THE VEHICLE HAS NOT YET BEEN REPAIRED ACCORDING TO THE RECALL. THE MANUFACTURER DID NOT ASSIST. THE FAILURE AND CURRENT MILEAGES WERE 4,584.
Feb 9, 2009 · 4,584 miles
Structure › Body
I AM OWNER OF GREEN 2008 KLR. I BOUGHT IT IN JUNE OF 2008. IT IS COVERED UNDER KAWASAKI 1 YR MANUFACTURE WARRANTY. IT HAS CHRONIC RUBBER ROT ON THE WINDSHIELD SCREWS, AFTER ONLY 2 MONTHS OF USAGE, AND KAWASAKI AND THE KAWASAKI DEALER HAVE REFUSED TO REPLACE THE RUBBER UNDER THE WARRANTY. *TR
Jul 28, 2008 · 3,200 miles
Exterior lighting
MOTORCYCLE TURN SIGNALS (REAR) BREAK AND FALL TO HANG BY THE WIRES. *TR
May 27, 2008 · 500 miles
Structure › Body
NOT A INCIDENT YET. THE ISSUE IS THAT MULTIPLE RUBBER PARTS ON MY MOTORCYCLE ARE FAILING FROM "DRY ROT" WITHIN DAYS OF PURCHASE. THESE PARTS SECURE THE WINDSCREEN AND BODY PANELS IN PLACE AND PROTECT THE CLUTCH CABLE FROM DEBRIS. WHILE THE WIND SCREEN COMING LOOSE AT SPEED IS A SCARY THOUGHT THE CLUTCH CABLE COVER IS OF PARTICULAR CONCERN AS IT'S FAILING COULD ALLOW SAND ETC INTO THE CLUTCH CABLE AND PREVENT THE OPERATOR FROM ACTUATING THE CLUTCH MAKING THE VEHICLE UNSTOPPABLE. *TR
Jun 1, 2008 · 2 miles
Exterior lighting
1. THREE (3) TURN SIGNAL MOUNTS HAVE FAILED TO DATE, DURING NORMAL VEHICLE OPERATION. 2. FAILURES OCCURRED AT 1,800 MILES, 4,000 MILES, AND 7,300 MILES ON THE ODOMETER. MOUNTS FAIL IN NORMAL HIGHWAY OPERATION, LEADING TO TURN SIGNAL BULB/LENS/HALF-STALK DANGLING FROM THE WIRING. NO ACCIDENTS OCCURRED DUE TO THE FAILURES. 3. FIRST ONE REPLACE AT CONSUMER'S EXPENSE, SECOND REPLACED AT DEALERS EXPENSE, THIRD BEING DEBATED BY DEALER. THIRD UNIT STILL IN OWNER'S POSSESSION. *TR
Aug 30, 2008 · 7,300 miles
Exterior lighting
TURN SIGNALS FALLING OFF NEWLY PURCHASED KAWASAKI KLR-650 MOTORCYCLE. RUBBER MOUNT IS THIN AND HAS BEEN REPORTED TO BREAK AT THE WEB SITE KLR WORLD .COM. *TR
Jul 20, 2008 · 3,985 miles
Exterior lighting
RIGHT REAR SIGNAL LIGHT FELL OFF OF MY MOTORCYCLE. UPON FURTHER INSPECTION AND CONSULTING WITH OTHER OWNERS OF THE SAME MOTORCYCLE I REALIZED THAT THIS IS NOT AN ISOLATED INCIDENT. I HAD NO DAMAGE TO MY BIKE, NO COLLISIONS, ETC. THE SIGNAL LIGHT RUBBER AND MOUNTING POINT ARE WEAK, CAUSING THEM TO COLLAPSE WITH NO WARNING, LEAVING THE RIDER WITHOUT SIGNAL LIGHTS. *TR
Oct 10, 2007 · 600 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.