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.
Safety risk
THIS COULD RESULT IN LOSS OF ELECTRICAL POWER TO THE ENGINE CREATING A RISK OF A CRASH RESULTING IN INJURY OR DEATH.
Manufacturer remedy
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 cooling: exhaust system: manifold/header/muffler/tail pipe
Manufacturer
KAWASAKI MOTORS CORP., U.S.A.
Vehicles affected
16,167
Reported to NHTSA
2009-02-19
Owners notified
2009-02-23
Defect description
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.
Safety 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.
Manufacturer remedy
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 cooling: exhaust system: manifold/header/muffler/tail pipe
Manufacturer
KAWASAKI MOTORS CORP., U.S.A.
Vehicles affected
33,693
Reported to NHTSA
2007-10-16
Owners notified
2007-10-22
Defect description
ON CERTAIN MOTORCYCLES, INSUFFICIENT TIGHTENING OF THE MUFFLER MOUNTING BOLTS COULD ALLOW THE BOLTS TO LOOSEN.
Safety risk
IF THE BOLTS LOOSEN COMPLETELY, IT IS POSSIBLE FOR THE MUFFLER TO SEPARATE FROM THE MOTORCYCLE AND CREATE THE POTENTIAL FOR A CRASH.
Manufacturer remedy
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.
Owner complaints
A complaint is one person's report to a federal agency. It is not a finding.
Component
Complaints
Median mileage
Exterior lighting
6
1,200 mi
Structure: body
2
2 mi
Electrical system
1
11,700 mi
Engine and engine cooling
1
—
Engine and engine cooling: exhaust system
1
4,584 mi
Exterior lighting: turn signal
1
—
Power train: manual transmission
1
—
Visibility: rearview mirrors/devices: exterior
1
—
The 2009 model has 2 times as many complaints as this one. These figures reflect raw complaint counts, not failure rates. Higher-selling model years naturally receive more complaints.
Safety recall repairs are provided free of charge by franchised dealers, regardless of vehicle age or mileage. This page displays aggregated data for the model year. To check recall status for a specific vehicle, search its VIN at nhtsa.gov.