2001 Kawasaki KLR650 engine problems

Filed Nov 16, 2016 · Engine · 7,239 miles · VT

Cam chain adjuster otherwise know as a doohickey. If it fails it may cause the engine to seize up without warning, I change mine after it broke but did not cause massive internal damage I was unaware that mine had failed I did the change as preventative maintenance this problem has been known to the klr community for many years but kawasaki refuses to recognize it, do a google search on doohickey for more info

Filed Apr 5, 2012 · Engine · 12,800 miles · UT

The idler shaft lever (aka "doohickey") broke in half and the pieces of it were floating around in the crank cased. This is very dangerous because if a piece of the idler shaft lever gets caught in the counterbalance chain or causes a crank bearing failure the engine could lock up at speed causing a crash. I replaced the idler shaft lever with a stronger aftermarket component.

Filed Aug 17, 2009 · Engine · 20,000 miles · 00

The idle shaft lever in my 2001 kawasaki klr650 had completely broken into 2 pieces. I discovered this when upgrading the part. It could have caused catastrophic engine failure.

Filed Jun 14, 2007 · Engine · KS

After 14,000 miles of use I am the second owner of the motorcycle the idle shaft lever failed. With the frequency of this failure being reported, there should be a tsb issued.

Filed Jul 16, 2006 · Engine · KS

When I tore into my 2001 klr 650 to inspect and replace the faulty "doohickey". I found the factory one broke. Both the spring and balancer were broke and I did not find either part in the motor. They are still floating around in the motor somewhere. There was scaring on the parts inside the motor where you could tell it had hung up on other moving parts and luckily did not lock up the motor. I replaced the "doohickey" with an aftermarket better product and hope the loose pieces do not float into moving parts to tear up my motor.

Filed Jun 25, 2006 · Engine · 13,000 miles · KY

Doohickey and spring on the counter balancer of the engine with 14000 miles was broken during motorcycle usage. This is a suggest replacement part that is recognized by owners of kawasaki klr 650 , so when I took mind apart to replace it, it was broken and the spring was also missing into the engine compartment that could cause the motor to lock up.

Filed Feb 1, 2006 · Engine · 21,000 miles · CA

Vehicle was a 2001 kawasaki klr 650 motorcycle. Dismantled engine case and found balancer chain tensioner broken into three pieces. Had to rummage through the crankcase to find two of the pieces. The tensioner spring was also broken. Piece of spring not found.

Filed Oct 11, 2004 · Engine · 9,940 miles · WA

Changed oil and discovered pieces of metal in crankcase. Had a broken idler shaft lever that split in two. Luckily it did not give way while I was running and seize the engine. Design flaw in the idler shaft lever weld resulted in failure.

Filed Jan 6, 2004 · Engine · 19,357 miles · CA

Balancer shaft failure on a 2001 kawasaki klr 650 motorcycle.

Filed Sep 16, 2003 · Engine · CA

Idler shaft lever retainer came apart inside engine, caused spring to fail early which also came apart inside engine. This is a known problem with these machines so I did a check to see and discovered this. I found all the little pieces ready to be sucked up into the oil pump which would have caused the engine to seize.