NHTSA Complaint #11015272 — 2000 KAWASAKI KL650A14

THE ENGINE BALANCER LOCKING MECHANISM FAILED EARLY ON THIS ENGINE - AND ON MANY OF THE KLR650S FROM 1987 - 2007 USING THE MODEL A DESIGNATION. MINE WAS AN A14 IN THE '86-'07 KLR65'S CHAIN-DRIVEN BALANCER SUBSYSTEM, TWO RELATED PARTS ARE PRONE TO FAILURE: 1) THE BALANCER IDLER LEVER (KAWASAKI PART NO. 13168-1436); AND, 2) THE IDLER SHAFT SPRING (KAWASAKI PART NO. 92144-1860). THE TWO PARTS SERVE TO MAINTAIN TENSION ON THE BALANCER CHAIN. THE OEM IDLER SHAFT LEVER IS A WELDED PIECE. BECAUSE IT IS IMPROPERLY SUPPORTED, THE LEVER CAN BE EASILY CRIMPED, DENTED, OR WARPED. EVENTUALLY, THE DAMAGE CAN BECOME SO SEVERE THE LEVER ???HANGS??ť ON THE CRIMPED PART AND FAILS TO ALLOW ADJUSTMENT TO THE CHAIN TENSION. IN SOME CASES THE WELD FAILS OR THE COLLAR BREAKS SO THE LEVER IS NO LONGER ATTACHED TO THE IDLER SHAFT AND PIECES FALL INTO THE OIL SUMP BELOW. TENSION ON THE SYSTEM IS NOW HELD ENTIRELY BY THE IDLER SHAFT SPRING. UNDER TREMENDOUS STRESS, THE SPRING CAN FAIL EITHER BY BREAKAGE OR BEING STRETCHED BEYOND LIMITS. IN ANY OF THE ABOVE SCENARIOS, WHEN TENSION IS LOST THE CHAIN IS CAPABLE OF JUMPING A SPROCKET, JAMMING AND LOCKING THE ENGINE. IT IS ALSO POSSIBLE FOR THE BROKEN PIECES TO FIND THEIR WAY INTO THE OIL PUMP (ASSUMING THE PROTECTIVE SCREEN IS MISSING) AND CAUSE ENGINE FAILURE AT SPEED.