NHTSA Complaint #10334914 — 2008 KAWASAKI KLR650 ENGINE AND ENGINE COOLING

Complaint Details

ODI Number	10334914
Vehicle	2008 KAWASAKI KLR650
Component	ENGINE AND ENGINE COOLING
Date of Incident	June 5, 2010
Date Filed	June 6, 2010
Mileage	16,300 miles
Crash	No
Fire	No
Injuries	0
Deaths	0
Vehicle Towed	No
State	IL

Consumer Description

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. *TR

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Other ENGINE AND ENGINE COOLING Complaints

#10434053 — November 3, 2011 — THE STARTER IDLER GEAR SHAFT HOLE/SLEEVE IS BORE/MILLED TO DEEP ON THE OUTSIDE CASING. THE SHAFT MOVES TO THE CASING ...

#10334707 — June 5, 2010 — THE SAFETY ISSUE IS ON A 2008 KAWASAKI KLR-650. THE STARTED GEAR IS GRINDING WHEN I TRY TO CRANK THE BIKE. THE DEALE...

#10334599 — June 4, 2010 — THE STARTER GEAR SHAFT CAN MIGRATE OUT IN THE LEFT SIDE ENGINE COVER, LEAVING THE GEAR UNSUPPORTED ON THE INBOARD SID...

#10334646 — June 4, 2010 — COVER SIDE HOLE THAT LOWER STARTER GEAR PIN RIDES IN IS MILLED TOO DEEP AND CAN RESULT IN SEVERE ENGINE DAMAGE. WHIL...

#10313024 — February 23, 2010 — 2008 KAWASAKI KLR 650 ENGINE USES AN ABNORMAL AMOUNT OF OIL, LEADING TO ENGINE SEIZURE/FAILURE/COSTLY DAMAGE. *TR

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