1999 KAWASAKI KLR650 — Problems, Recalls & Safety Data

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

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

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

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.

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