NHTSA vehicle safety data

2005 Kawasaki KL650A Recalls & Complaints

The 2005 Kawasaki KL650A has 1 NHTSA recall campaign and 2 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Kawasaki dealer.

NHTSA recall and complaint data for the 2005 Kawasaki KL650A. Recall data is refreshed daily from NHTSA.

2005 Kawasaki KL650A owner complaints

Owners have filed 2 complaints with NHTSA about the 2005 Kawasaki KL650A, describing incidents dated August 4, 2009 to September 27, 2014.

Most-cited components

Engine 2 complaints

Newest complaints

ODI #10643472 · Filed October 9, 2014
BALANCER CHAIN BEGAN MAKING NOISE ATTEMPTED FACTORY RECOMMENDED ADJUSTMENTS. CONCERN WAS UNRESOLVED. REMOVED STATOR COVER FOUND QUADRANT AND TENSIONER BROKEN. *TR
ODI #10279419 · Filed August 5, 2009
ON THE BASIS OF ANECDOTAL INFORMATION I REPLACED THE STOCK BALANCER CHAIN TENSIONER ON MY 2005 KAWASAKI KLR 650 MOTORCYCLE. THESE HAVE BEEN KNOWN TO HAVE PROBLEMS IN THIS AREA, AND SURE ENOUGH THE SPRING THAT IS TO TENSION THE BALANCE CHAIN AS IT WEARS WAS BROKEN AND INOPERATIVE. THIS MEANT THAT IF…

Read all 2 complaints

MUFFLER MOUNTING BOLTS

NHTSA #07V486000 · Engine and Engine Cooling — Exhaust System — Manifold/Header/Muffler/Tail Pipe · NHTSA notice

Reported October 16, 2007 · KAWASAKI MOTORS CORP., U.S.A.

Potentially affected: 33,693 vehicles

Owners notified October 22, 2007 · Vehicles built June 8, 2001 – July 11, 2007 (per NHTSA)

Defect description

ON CERTAIN MOTORCYCLES, INSUFFICIENT TIGHTENING OF THE MUFFLER MOUNTING BOLTS COULD ALLOW THE BOLTS TO LOOSEN.

Safety consequence

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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

try.vin has no NCAP crash-test rating on file for the 2005 Kawasaki KL650A. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

2 owner complaints have been filed with NHTSA for the 2005 Kawasaki KL650A.

Engine

ODI #10643472

Incident: September 27, 2014 · Filed: October 9, 2014

BALANCER CHAIN BEGAN MAKING NOISE ATTEMPTED FACTORY RECOMMENDED ADJUSTMENTS. CONCERN WAS UNRESOLVED. REMOVED STATOR COVER FOUND QUADRANT AND TENSIONER BROKEN. *TR

Engine and Engine Cooling

ODI #10279419

Incident: August 4, 2009 · Filed: August 5, 2009

ON THE BASIS OF ANECDOTAL INFORMATION I REPLACED THE STOCK BALANCER CHAIN TENSIONER ON MY 2005 KAWASAKI KLR 650 MOTORCYCLE. THESE HAVE BEEN KNOWN TO HAVE PROBLEMS IN THIS AREA, AND SURE ENOUGH THE SPRING THAT IS TO TENSION THE BALANCE CHAIN AS IT WEARS WAS BROKEN AND INOPERATIVE. THIS MEANT THAT IF I HAD NOT REPLACED THE TENSIONER ADJUSTER AND SPRING, THE CHAIN THAT RUNS THE BALANCER WOULD HAVE CONTINUED TO WEAR AND STRETCH TO THE POINT OF POSSIBLE CATASTROPHIC FAILURE. IT IS NICE THAT AMERICANS ARE MAKING A LIVING MAKING THESE PARTS, BUT HOW MANY BIKES DO NOT GET THIS REPAIR. I MENTION THIS AT DEALERSHIPS AND THEY ACT LIKE I AM SPEAKING A FOREIGN LANGUAGE. *TR

Other Kawasaki KL650A model years

Check your 2005 Kawasaki KL650A VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Kawasaki KL650A at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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