2002 Kawasaki Klr650 problems, complaints & recalls
Most-reported problem areas: Engine And Engine Cooling (5) · Visibility:rearview Mirrors/Devices:exterior (1) · Tires (1)
🧭 Reliability snapshot
Compared against other Kawasaki Klr650 model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (1)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Structure 2024-01-25 · MC24-01 · Service Bulletin/Repair Instructions
service information about a shipping bracket attaching the motorcycle to the crate can cause damage to the motorcycle fuel tank if removed.
What owners report
2009-02-12 · Suspension“i have a 2002 kawasaki klr 650 with 6053 miles i am trying to sell it but no one wants it with out the balancer upgrade aka doohickey. i did mine today and found the spring broken. the tail end was missing. i know alot of people have been affected by this bad part inc. the balancer itself. i don't know what kind of damage the broken spring did …”
2007-04-11 · Engine And Engine Cooling · 9,000 mi“i own a 2002 kawasaki klr650 with approximately 9500 miles on it. i was riding at low speed on the date below when i heard a loud metal clang in the engine and the motorcycle came to a screeching halt. luckily, i was only traveling at 30 mph and i was not in traffic. the cause of the incident was not immediately known. when i brought the moto…”
2006-05-17 · Engine And Engine Cooling:engine:gasoline“kawasaki klr650's have a problem with an engine balancer lever breaking. i have a 2002 klr and found my lever to be broken in three places. although it did not cause a crash in this case, the broken pieces could easily cause an accident (and have in the past). you certainly do not want this piece to break while you on the high way. it is well known…”
2005-12-08 · Engine And Engine Cooling“dt: the contact stated the engine counter balance part on motorcycle failed. the contact purchased an after market part and replaced the failed one at his own expense. the motorcycle was not seen by a dealer. *ak …”
2005-01-08 · Engine And Engine Cooling · 3,000 mi“balancer tensioner spring failed. i had read reports on the internet desctibing the balancer tensioner system as being prone to failure. i found that the tensioner spring had broken where it attaches to the engine case. the motorcycle has 6706 miles on it. i am replacing the spring and tension adjuster with an improved aftermarket kit. the fai…”
2003-11-22 · Engine And Engine Cooling:engine · 16,500 mi“subject: 2002 kawasaki klr650. november 2003, 16,500+ miles: davis service center, montrose, colorado, was asked to replace the stock counterbalancer chain tensioner lever with a stainless steel upgrade from eagle manufacturing & engineering. this was to be preventive maintenance since i've heard from that this is a weak point. upon internal inspec…”
2003-09-29 · Engine And Engine Cooling“balancer idle chain adjuster failed while driving the motorcycle. dealer notified. *ak…”
2003-07-02 · Tires“motorcycle is under 5000 miles and already has changed front and rear tires. dunlop tire, model 750, size 130/80-1765s, and problem stillrecurring, tire got flat.*ak…”
2003-03-05 · Engine And Engine Cooling:cooling System · 300 mi“nar 03/05/2003 after three consecutive trips to the repairs shop within 30 days for engine oil leak the consumer no longer wants the vehicle. *cb …”
2003-01-01 · Engine And Engine Cooling · 2,867 mi“the balancer idler shaft tensioning sprong was discovered to be broken when preventive maintenance was carried out on my 2002 kawasaki klr 650 motorcycle at 2867 miles. potentially, this failure could have caused the engine to sieze whilst in operation.…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.