NHTSA Complaint #10187570 — 2002 KAWASAKI KLR650

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 MOTORCYCLE INTO THE REPAIR SHOP, I OBSERVED AFTER THE ENGINE WAS OPENED THAT THE IDLER SHAFT LEVER , A WELDED PIECE OF STEEL, SNAPPED IN HALF, SENDING BOTH BROKEN PIECES INTO THE LOWER END OF ENGINE, AND DISLODGING THE BALANCER CHAIN FROM THE SPROCKET, WHICH CAUSED NEAR-CATASTROPHIC DAMAGE TO THE ENGINE. AFTER SIGNIFICANT TIME AND FINANCIAL INVESTMENT, 40% OF THE TOTAL VALUE OF THE MOTORCYCLE, IT WAS PUT BACK ON THE ROAD HAVING BEEN REPAIRED WITH ONLY KAWASAKI FACTORY PARTS AND RAN FINE FOR A TIME. ABOUT 2000 MILES LATER, I WAS DOING ROUTINE MAINTENANCE WHEN I NOTICED A PIECE OF METAL ATTACHED TO THE MAGNETIC OIL PLUG. AFTER SOME INVESTIGATION I FOUND THIS TO BE A PIECE OF THE NEWLY INSTALLED IDLER SHAFT LEVER. ONCE AGAIN THE PIECE NEEDED TO BE REPLACED. HAD I NOT INSTALLED A MAGNETIC OIL PLUG ANOTHER MAJOR PROBLEM MOST DEFINITELY WOULD HAVE OCCURRED.*AK