NHTSA vehicle safety data

2003 Kawasaki KLR650 Recalls & Complaints

We couldn't confirm the NHTSA recall list for the 2003 Kawasaki KLR650 right now, so this page doesn't state a recall count — check the VIN at nhtsa.gov/recalls for current campaigns. 6 owner complaints are on file.

NHTSA recall and complaint data for the 2003 Kawasaki KLR650.

2003 Kawasaki KLR650 owner complaints

Owners have filed 6 complaints with NHTSA about the 2003 Kawasaki KLR650, describing incidents dated August 23, 2003 to October 2, 2010.

Most-cited components

Engine 5 complaints
Steering 1 complaint
Tires 1 complaint

Newest complaints

ODI #10358886 · Filed October 2, 2010
KLR650 ENGINE IDLE LEVER ADJUSTER SPRING FAILED SENDING METAL FRAGMENTS THROUGH OUT THE ENGINE THAT I HAD TO FISH OUT - VERY VERY COMMON PROBLEM TO THE POINT THAT IT IS THE FIRST THING PEOPLE DO WHEN THEY BUY A KLR OF ANY YEAR. *TR
ODI #10266451 · Filed April 23, 2009
KAWASAKI KLR 650 MOTORCYCLE CHAIN TENSIONER COUNTER BALANCER AND RETAINER SPRING BROKEN AND MISSING. THE BROKEN PIECES CAN CAUSE CATASTROPHIC FAILURE INCLUDING ENGINE SEIZURE WHILE IN OPERATION. REPLACED THE PARTS FROM AFTERMARKET SUPPLIER. *TR
ODI #10197781 · Filed July 30, 2007
I HAVE A 2003 KAWASAKI KLR650 AND THE BALANCER LEVER ADJUSTER IS BROKEN. IT MAKES A LOUD NOISE AND THERE IS A POSSIBILITY OF ENGINE SEIZURE. I HAVE DONE NOTHING TO FIX THIS YET AND AM DRIVING AN ALTERNATE VEHICLE. *JB

Read all 6 complaints

We couldn't confirm the NHTSA recall list for the 2003 Kawasaki KLR650 right now — this is not a confirmed "no recalls". Check the VIN at NHTSA.gov/recalls for the official status.

try.vin has no NCAP crash-test rating on file for the 2003 Kawasaki KLR650. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

6 owner complaints have been filed with NHTSA for the 2003 Kawasaki KLR650.

Engine and Engine Cooling

ODI #10358886

Incident: October 2, 2010 · Filed: October 2, 2010

KLR650 ENGINE IDLE LEVER ADJUSTER SPRING FAILED SENDING METAL FRAGMENTS THROUGH OUT THE ENGINE THAT I HAD TO FISH OUT - VERY VERY COMMON PROBLEM TO THE POINT THAT IT IS THE FIRST THING PEOPLE DO WHEN THEY BUY A KLR OF ANY YEAR. *TR

Engine and Engine Cooling

ODI #10266451

Incident: April 21, 2009 · Filed: April 23, 2009

KAWASAKI KLR 650 MOTORCYCLE CHAIN TENSIONER COUNTER BALANCER AND RETAINER SPRING BROKEN AND MISSING. THE BROKEN PIECES CAN CAUSE CATASTROPHIC FAILURE INCLUDING ENGINE SEIZURE WHILE IN OPERATION. REPLACED THE PARTS FROM AFTERMARKET SUPPLIER. *TR

Engine and Engine Cooling

ODI #10197781

Incident: July 28, 2007 · Filed: July 30, 2007

I HAVE A 2003 KAWASAKI KLR650 AND THE BALANCER LEVER ADJUSTER IS BROKEN. IT MAKES A LOUD NOISE AND THERE IS A POSSIBILITY OF ENGINE SEIZURE. I HAVE DONE NOTHING TO FIX THIS YET AND AM DRIVING AN ALTERNATE VEHICLE. *JB

Steering; Engine and Engine Cooling

ODI #10147202

Incident: January 8, 2006 · Filed: January 8, 2006

I JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKEY AND SPRING FROM ARROWHEAD MOTORSPORTS. *JB

Tires

ODI #10081619

Incident: May 5, 2004 · Filed: July 9, 2004

WHEN THE MOTORCYCLE WAS TAKEN OUT OF STORAGE CONSUMER NOTICED THAT TIRES SIDEWALL DEVELOPED WEATHER CHECKS. THESE WERE SMALL CRACKS THAT WENT AROUND THE SIDEWALL OF THE TIRES. THE MOTORCYCLE WAS DRIVEN FOR 6 MONTHS, THEN STORED FOR 6 MONTHS PRIOR TO THIS PROBLEM OCCURRING. DEALERSHIP WAS CONTACTED BUT COULD NOT IDENTIFY WHAT CAUSED THE CRACKS TO OCCUR BECAUSE THE MOTORCYCLE WASN'T STORED NEXT TO ANY CHEMICALS. THE FRONT TIRE SIZE WAS 90/90-21 AND THE REAR TIRE SIZE WAS 130/80-17. THE MODEL NAME LISTED ON TIRE WAS K750.*AK

Engine and Engine Cooling

ODI #10038446

Incident: August 23, 2003 · Filed: October 12, 2003

THE MOTORCYCLE CAM CHAIN ADJUSTER SPRING BROKE AND CAUSED THE VEHICLE TO STALL WHILE DRIVING. SAUSAGE, KLR 650, 2003. *AK WHILE DRIVING CONSUMER HEARD A GRINDING SOUND FROM THE LEFT SIDE OF THE ENGINE. THE BROKEN SPRING BENT THE INTAKE VALVE AND DAMAGED VALVE GUIDES (SAUSAGE 630 2003). *TS *NLM

Check your 2003 Kawasaki KLR650 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Kawasaki KLR650 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

Check a Kawasaki VIN