2008 Kawasaki KLR650 engine problems

Filed Jun 18, 2012 · Engine · 6,022 miles · IL

The engine burns oil excessively at highway speeds (60 to 70 MPH). An engine lockup due to lack of lubricant is a very real concern due to the oil consumption rate.

Filed Nov 3, 2011 · Engine, Transmission · 17,000 miles · AK

The starter idler gear shaft hole/sleeve is bore/milled to deep on the outside casing. The shaft moves to the casing side and loses contact with the inside bushing/sleeve, wich forms a gap at the main housing side. There is now enough space for the spacer washer to fall into the bottom-end and cause huge/catastrophic failure.

Filed Aug 13, 2010 · Engine · 5,400 miles · CO

Tl*the contact owns a 2008 kawasaki klr650. While traveling 65 MPH the contact noticed that the vehicle had suddenly shut off without warning. The vehicle was taken to the dealer where the contact was informed that the engine needed to be replaced due to oil leaks. The vehicle was not repaired and there were no prior warnings. The current and failure mileages were 5400.

Filed Jun 6, 2010 · Engine · 16,300 miles · IL

2008 kawasaki klr 650 starter gear cover is improperly bored allowing support shaft to become unsupported on one end. This could cause thrust washers to drop into the rotating flywheel at speed, locking the motor and causing loss of control. Older and newer models both have a ridge in the outer engine cover that prevents the idler gear shaft from drifting out too far and loosing support in the inner engine cover. This was clearly a machining error. I inserted a small spacer in the hole to prevent the shaft from moving.

Filed Jun 5, 2010 · Engine · GA

The safety issue is on a 2008 kawasaki klr-650. The started gear is grinding when I try to crank the bike. The dealer will not fix the issue. The cause of the failure is a deep bore on the side cover that holds the gear. It is a mfg issue. My concern is when the gear lock up? There is a good chance it could lock up as I'm riding down the rode.

Filed Jun 4, 2010 · Engine · 6,100 miles · NY · fire

Cover side hole that lower starter gear pin rides in is milled too deep and can result in severe engine damage. While installing a balancer tension spring upgrade (another issue with these motorcycles) I found I had this issue. I had to install a spacer to fix and prevent the other side from coming out of engine side hole and causing damage.

Filed Jun 4, 2010 · Engine · 3,500 miles · AZ

The starter gear shaft can migrate out in the left side engine cover, leaving the gear unsupported on the inboard side and allowing a washer to migrate loose into the engine--potentially causing the transmission to lock up or the timing chain to skip teeth and cause the intake or exhaust valves to hit the piston top, bending valves and making the engine inoperable.

Filed May 11, 2010 · Electrical, Engine · WA

2008 kawasaki klr 650 motorcycle. Consumer states several problems with motorcycle and has received recalls *tgw since purchasing the motorcycle, the consumer had to replace three batteries. While changing the oil for the first time, he discovered the engine was consuming eight to ten ounces of oil per thousand miles of use. The consumer contacted the manufacturer and was informed the oil consumption fell within the acceptable range as specified by kawasaki engineers. The consumer believed the pistons were too small for the cylinder bore on his bike.

Filed Feb 23, 2010 · Engine · 7,500 miles · NV

2008 kawasaki klr 650 engine uses an abnormal amount of oil, leading to engine seizure/failure/costly damage.

Filed Mar 2, 2009 · Engine · 2,500 miles · IN

Tl*the contact owns a 2008 kawasaki klr650. The contact received a recall notice for the federal safety agency campaign id number 09v059000 (engine and engine cooling:exhaust system:manifold/header/muffler/tail pipe) and immediately called the dealer. The dealer stated that the vehicle should not be driven because the bolts could loosen completely and the muffler could possibly separate from the vehicle, causing a crash or serious injury. The dealer also stated that they would not pay for towing. The contact does not want to have the vehicle repaired if he has to pay for towing. The vehicle has not yet been repaired. The failure and current mileages were 2,500.