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.
The worst 2003 Kawasaki KLR650 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Engine5
- Steering1
- Tires1
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Engine5
- Steering1
- Tires1
Recalls
No recalls on record for this model year.
Technical service bulletins for the 2003 Kawasaki KLR650 1
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
What 2003 Kawasaki KLR650 owners say
Most recent owner complaints, unedited.
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.
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.
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.
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.
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
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Questions about the 2003 Kawasaki KLR650
Is the 2003 Kawasaki KLR650 reliable?
Owners have filed 6 complaints about the 2003 Kawasaki KLR650, close to a typical KLR650 model year.
What is the most common problem with the 2003 Kawasaki KLR650?
Engine and cooling, with 5 complaints, typically around 10,265 miles. Next is steering (1).
How many recalls does the 2003 Kawasaki KLR650 have?
No recalls on record.
What year does the Kawasaki KLR650 have bad engine?
The Kawasaki KLR650 model years with the most engine complaints are 2001 (15 complaints) and 2008 (13 complaints).
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