NHTSA Complaint #10247179 — 2008 KAWASAKI KLR650

THE CONDITIONS HEREIN MAY CAUSE AN ENGINE FAILURE. THIS FAILURE COULD CAUSE THE ENGINE TO SEIZE WHICH COULD CAUSE THE LOSS OF CONTROL OF THE VEHICLE [MOTORCYCLE]. THE VEHICLE WAS IN USE UNDER NORMAL "STREET" CONDITIONS. HIGH OIL CONSUMPTION DUE TO MANUFACTURING DEFECT/ WORKMANSHIP. 1 QUART+ OF OIL PER 300 MILES, RESULTING IN HIGH AIR POLLUTION & POSSIBLE ENGINE SEIZURE---FROM THE LOSS OF OIL! PISTON RINGS LEAK OIL. THERE IS ALSO A GROOVE IN ENGINE'S CYLINDER WALL [3"L X 5/32"W X 1/64"D] DUE TO IMPROPER PART ASSEMBLY [PISTON'S WRIST PIN CLIP; A FACTORY DEFECT]. THE ENGINE'S EXHAUST VALVES LEAK WHICH ALSO PRODUCES POOR AIR QUALITY CONTROL. THESE CONDITIONS ARE INTERNAL TO THE ENGINE AND WERE CREATED DURING THE MANUFACTURING PROCESS. THESE FAILURES CAN ONLY BE DETERMINED THROUGH THE DISASSEMBLY OF THE ENGINE. THE ABOVE VEHICLE'S HAS ONLY BEEN USED FOR 2,085 [2K] MILES. IT IS A 2008 MODEL YEAR. THE ABOVE ENGINE FAILS TO MEET AIR QUALITY STANDARDS. THE COST OF REPAIR IS BEING ESTIMATED BETWEEN $800-1000. THIS ENCOMPASSES PARTIAL VEHICLE DISASSEMBLE, UPPER ENGINE DISASSEMBLE, MACHINE SHOP WORK, REPLACEMENT PARTS, ENGINE REASSEMBLE, AND THE REASSEMBLE OF THE AREA AROUND THE ENGINE [IT'S A MOTORCYCLE]. TO CORRECT THE ABOVE FAILURES NEW PARTS MUST BE INSTALLED ALONG WITH NECESSARY MACHINING OF ENGINE'S CYLINDER. *TR