Model year record

2009 Kawasaki KL650E recalls & problems

The 2009 Kawasaki KL650E has 2 safety recalls and 6 owner complaints on file with NHTSA. The most-reported problem area is electrical system (4 complaints).

Recalls2safety recalls

Complaints6filed 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.

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	Crashes	Fires	Injuries	Typical mileage*
Electrical systemWiring	4	0	0	0	6,375 mi
Engine and engine coolingEngine	2	0	0	0	—

*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 2009 KAWASAKI KL650E MOTORCYCLE. 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. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 1,600.
Aug 29, 2012 · 1,600 miles
Electrical system
TL* THE CONTACT OWNS A 2009 KAWASAKI KL650E. 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. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR DIAGNOSTIC TESTING. THE PREVIOUS OWNER REPLACED THE WIRING HARNESS DUE TO SIMILAR FAILURES. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 6,350.
Oct 10, 2011 · 6,350 miles
Engine and engine cooling › Engine
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. *KB
Jul 17, 2011 · 7,000 miles
Electrical system › Wiring
TL*THE CONTACT OWNS A 2009 KAWASAKI KL650E MOTORCYCLE. 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). THE VIN WAS NOT INCLUDED IN THE RECALL DEFECT AND THE REPAIR WOULD BE AT THE OWNER'S EXPENSE. THE VEHICLE WAS IN THE PROCESS OF BEING REPAIRED. THE FAILURE MILEAGE WAS 8,500.
Sep 1, 2010 · 8,500 miles
Electrical system
THE WIRING HARNESS RUBBED IN TWO DIFFERENT PLACES ON THE MOTORCYCLE THAT LEAD TO A NEUTRAL LIGHT STAYING ON AND THE TURN SIGNAL TO NOT ACTIVATE. THE BIKE WIRING HARNESS HAD A PREVIOUS RECALL THAT WAS COMPLETED BY KAWASAKI ON MARCH OF 2009. KAWASAKI FACTORY REP. CAME IN TO THE DEALERSHIP TO INVESTIGATE AND TOOK PHOTOS AND SAMPLES OF THE FAILED COMPONENTS TO SEND BACK TO THE ENGINEERS. THEY REPLACED THE WIRING HARNESS AND USED A NEW TYPE (UNKNOWN) OF PROTECTIVE COVERING ON IT. KAWASAKI WAS CONCERNED BECAUSE THEY HAVE BEEN NOTICING A SHARP INCREASE OF THIS ISSUE. THERE IS A MOTORCYCLE AT THE DEALERSHIP WITH THE SAME MILES/MODEL/YEAR THAT HAD THE SAME ISSUE AND HAD KILLED THE ENGINE WHILE AT…
Nov 27, 2009 · 6,400 miles
Engine and engine cooling
NEW 09 KAWASAKI KLR650 BOUGHT FROM RIDERSVILLE CYCLE IN BERKELEY SPRINGS, WV. ON INITIAL RIDE OIL DRAIN PLUG CAME OUT, DRAINING OIL, LEADING TO ENGINE SEIZING WHILE TRAVELING AT 55MPH, BUT FOR THE QUICK REACTIONS OF THE RIDER, A SERIOUS ACCIDENT WOULD HAVE PURSUED. DEALER/MANUFACTURER ERROR FOR NOT CHECKING BOLT TIGHTNESS, AS 2 QUARTS OF OIL HAD TO BE ADDED TO BIKE UPON PICKUP, INDICATING THE BOLT WAS ALREADY LOOSE AND OIL HAD LEAKED OUT, AS THE BIKES ARE DELIVERED FULL ACCORDING TO KAWASAKI. OIL CAPACITY OF BIKE IS 2.6 QTS. OR MANUFACTURE DEFECT IN DESIGN OF BIKE, BY NOT BUILDING IT WITH A SKID PLATE THAT PROTECTS THE BOLT AND BOTTOM OF CRANKCASE FROM IMPACT. SOMETHING THEY READILY ADMIT…
Oct 11, 2009 · 180 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.