RoadVitals

1999 Kawasaki KLR650

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
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Latest May 7, 2011
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
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InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
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Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
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Overview

Our database contains 7 NHTSA owner-reported complaints for the 1999 Kawasaki KLR650, most frequently naming the engine category. 1 manufacturer communication is on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

  • Engine7100.0%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

No recalls in our database for this model year

That does not guarantee a specific vehicle is unaffected — recalls are issued against VINs, and new campaigns are announced regularly. Check a VIN on NHTSA.gov.

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

Engine
Filed May 7, 2011

THE 1986-2007 KAWASAKI KLR650 MOTORCYCLE'S TENSIONING SYSTEM FOR THE ENGINE BALANCER SHAFT DRIVE CHAIN IS UNRELIABLE, AND A FAILURE COULD LEAD TO SUDDEN ENGINE LOCK-UP AND LOSS OF VEHICLE CONTROL, POTENTIALLY RESULTING IN INJURY OR FATALITY. THE MOST TROUBLESOME PARTS OF THE BALANCER DRIVE ADJUSTING SYSTEM ARE THE IDLER SHAFT LEVER, P/N 13168-1436 AND THE SPRING, 92144-1860. THE BALANCER ADJUSTER IDLER RIDES ON AN ECCENTRIC SHAFT P/N 39115-1077, AND WHEN THE SHAFT ROTATES IT CHANGES HOW THE TENSION IDLER RELATES TO THE BALANCER CHAIN, ALLOWING THE CHAIN TO BE TENSIONED. THE RECOMMENDED PROCEDURE FOR ADJUSTMENT IS FOR THE USER TO LOOSEN A SCREW THAT HOLDS THE IDLER SHAFT LEVER, ALLOW THE SPRING TO PULL THE IDLER INTO ITS NEW POSITION, AND THEN RETIGHTEN THE SCREW. IF THE IDLER SHAFT LEVER FAILS THE SPRING IS INADEQUATE TO WITHSTAND THE CYCLIC LOADING AS THE CHAIN RUNS AT ENGINE SPEED, AND WILL LEAD TO FAILURE OF THE SPRING AND LOSS OF TENSION IN THE CHAIN. IF THE SPRING FAILS BETWEEN SERVICE INTERVALS BUT THE SYSTEM WAS PROPERLY TENSIONED TO BEGIN WITH, THE CHAIN WILL LOSE TENSION WHEN THE USER LOOSENS THE ADJUSTING SCREW. ALSO ON HIGHER MILEAGE VEHICLES THE SPRING CAN COME OFF ITS ATTACHING POINTS AS IT BECOMES TOO LONG FOR THE APPLICATION, CAUSING IT TO FALL INTO THE ENGINE. IN EITHER CASE THE FAILURE CAN RESULT IN THE BALANCER DRIVE CHAIN BECOMING EFFECTIVELY UNTENSIONED. THE CHAIN IS FREE TO COME OFF ITS SPROCKETS, OR TO BUNCH UP AROUND THE CRANKSHAFT SPROCKET THAT DRIVES IT, OR TO SOMETIMES CATCH ON THE DRIVE SPROCKET AND SOMETIMES SLIP LEADING TO RAPID SPROCKET AND CHAIN WEAR CREATING METAL DEBRIS INSIDE THE ENGINE. IF THE CHAIN BECOMES BUNCHED UP AROUND THE CRANKSHAFT SPROCKET IT COULD LOCK UP THE ENGINE AND MAKE THE VEHICLE SUDDENLY IMMOBILE AND UNCONTROLLABLE. *TR

NHTSA ID
10399440
Incident
May 7, 2011
Mileage
49,247 mi
Engine
Filed Feb 15, 2006

1999 KAWASAKI KLR650 MOTORCYCLE BALANCER ADJUSTER FAILURE >ENGINE LOCKUP & LOSS OF CONTROL . PARTS & LABOR TO REPAIR $1211.81 REPAIR DATE INVOICE DATE 5/24/05 INVOICE#99079450 HILLSIDE MOTORSPORTS RT14 WHITE RIVER JCT , VT 05001 MAYBE SAFETY ISSUE DUE TO SUDDEN ENGINE LOCK UP, BIKES NEED RECALL FOR IMPROVED BALANCER,TENSIONER ASSY. *JB

NHTSA ID
10150299
Incident
Oct 10, 2004
Mileage
19,400 mi
Engine
Filed Jan 3, 2006

DT: THE CONTACT STATED THAT THE DOOHICKEY CRACKED ON THE MOTORCYCLE. THE DOOHICKEY IS AN IDLER SHAFT LEVER WHICH PUTS TENSION ON THE CHAIN INSIDE THE ENGINE. THERE WERE NO WARNING OR INDICATORS OF A PROBLEM. THIS WAS DISCOVERED BY THE CONTACT WHEN DOING ROUTINE SERVICE. THE MOTORCYCLE WAS REPAIRED. *AK UPDATED 1/25/2006. *NM

NHTSA ID
10146794
Incident
May 21, 2005
Mileage
6,000 mi
Engine
Filed Jan 13, 2003

WITH LESS THAN 3,000 MILES ON MY 1999 KAWASAKI KLR 650, DURING A ROUTINE MAINTENANCE, A FAILED LEVER, IDLER SHAFT AND SPRING WAS DISCOVERED AND REPLACED WITH AN AFTER-MARKET PRODUCT. DURING THIS SAME MAINTENANCE ACTIVITY, TWO OTHER KLR 650'S WERE FOUND TO HAVE SUFFERED THE SAME FAILURE.

NHTSA ID
10000992
Incident
Oct 17, 2002
Mileage
2,900 mi
Engine
Filed Jan 12, 2003

BALANCER CHAIN BROKE CAUSING ENGINE TO LOCK UP AND LOCK UP THE REAR WHEEL

NHTSA ID
10000978
Incident
May 12, 2000
Mileage
74,000 mi
Engine
Filed Jul 5, 2002

I WAS RIDING ALONG IN TRAFFIC WHEN THE MOTOR SIZED UP LOCKING THE REAR WHEEL ALMOST GETTING ME KILLED FROM THE TRUCK BEHIND ME. THIS IS THE SECOND TIME THIS HAPPEND. IN 1993 I BOUGHT A NEW KLR650 AND RODE IT TILL 1999 WHEN THE MOTOR LOCKED UP ONE DAY WHEN COMMING HOME FROM WORK. IT COST ME $200.00 TOHAVE MY DEALER TELL ME THAT SOMETHING BROKE IN THE MOTOR AND WOULD COST ME ANOTHER $2000.00 TO FIX. SO I SOLD IT FOR PARTS. IT HAD 36000.MILES ON IT AND WENT OUT AND BOUGTT A LOW MILAGE 99. KNOW IT HAPPEND AGAIN I CONTACTED KAWASAKI THEY TOLD ME TO BRING IT TO MY DEALER AND LED ME TO BELIVE THEY WOULD PAY PART IF NOT ALL REPAIRS.BUT THAT IS NOT THE CASE. I NOW HAVE TO PAY FOR MY DEALERS TIME @ $60.00 PER HR I'M HAVING A USED ENGIN INSTALLED OT A COST OF $2200.00 AND DON'T THINK THIS IS RIGHT. I REACENTLY GOT A COMPUTER AND WENT ON LINE AND LEARNED THIS IS A WELL KNOWN PROBLEM WITH THIS MOTORCYCLE, AND KAWASAKI IS WELL AWAIR OF IT THEY MADE A SMALL MODIFACATION IN THE 1996 MODEL. *AK

NHTSA ID
763847
Incident
May 14, 2002
Engine
Filed Jun 28, 2002

IN 1993 I BOUGHT A NEW SKAWASAKI KLR650IT WAS ALWAYS MAINTAIND AS PER FACTORY SPEC. NO SAFETY DEFECT LISTED. *AK

NHTSA ID
763615
Incident
May 12, 2002

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

MC24-01

STRUCTURE

Service Information about a shipping bracket attaching the motorcycle to the crate can cause damage to the motorcycle fuel tank if removed.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Kawasaki KLR650 by model year
YearComplaintsRecallsInvestigationsIssue Index
2024100—
2023160038.4
2022100—
2018000—
2017100—
2009600—
20081161037.3
2007300—
2006100—
2005100—
2003600—
2002110029.0
2001190032.7
2000800—
1999Viewing700—
1998600—
1997100—
1995100—
1993200—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.