2023 KAWASAKI KLR650 — Problems, Recalls & Safety Data

This is a new Kawasaki KLR 650 motorcycle with 220 miles now on it and there is a steering issue at low speeds from 5 to 15 mph. It feels like the steering is catching and you have to fight the handlebars to get the motorcycle to turn. This is dangerous when starting off or at low speeds in traffic. After checking for recalls there are none but as I researched this problem I have found that most or all 2023 models are having this same problem if the VIN# starts with the letters ML. This means assembled in Thailand. Apparently the factory used incorrect torque settings when tightening the steering stem bolt or preload on steering stem bearing. I will be taking to dealer to have this dangerous issue checked.

When making a slow speed turn that requires a little extra handlebar input the bike seems to act like the steering head is stuck, gets briefly stuck in a "notch" and then releases making it very hard to be smooth in a slow speed trun which can be very dangerous depending on traffic/road way situation. Have read of several other new owners experiencing the same thing. This has been happening since the bike had a 100 or so miles on it.

I bought the motorcycle new from the dealer. At low speeds (12mph - 30 moh), the steering "catches" or "falls off" suddenly. Sometimes if feels like there are notches in the steering. I took it to the dealer to fix and they loosened the steering head nut above the head bearings. It seemed OK for about 50 miles and then came back even worse. Now the steering is so bad it is barley rideable.

Steering bearing overtorqued by factory, dealer warranty loostened and readjusted, initial tendency, failure to return to neutral, rough bearing feeling, caused many near misses with vehicles ahead, problem unresolved, I can feel it, dealer can not. Contra Costa Powersports, 1150 Concord Ave Ste 100, Concord, CA 94520 (925) 687-7742. Issue regarding drive train, false neutral. Potentially hazardous conditions occurred three times. Pulled over to adjust GPS, engine running, shifted to neutral, neutral light illuminated on dash, put the side stand down,, released the clutch bike still in gear, bike lunged forward, off of sidestand, bike headed for ground with rider, lucky first two times I had my hand on the front brake, lock up brake preventing bike from launching off the side stand and crashing to ground. First time with stock clutch and brake levers set up by dealer with 1/16 clutch free play, third time with Warp9 aftermarket adjustable brake and clutch levers, was in same 1/16" free play when set up, cable seated during 100 mile ride, gap then 1/4", third false neutral, dash displayed green neutral indication light, side stand down, released clutch, bike still in gear, this time hand not on brake lever, didn't anticipate bike movement, the bike launched forward off the sidestand, tried to eject me into the roadway. Could have been lethal consequences had I not recovered the bike before it dropped to the roadway, I just managed to get it back up and out of the roadway before cars came around the blind mountain turn. The Clutch lever being slightly out of adjustment had no impact on shifting gears, and didn't miss one gear change. Stock clutch lever or Warp9 aftermarket, clutch freeplay 1/16 to 1/4 made no difference. I can not replicate the hazard, it occurred randomly. Technically, weather the neutral light illuminates on the dash or not, in gear, deploying the side stand should kill the bike. Dealer can not duplicate what to we do now?

Steering bearing overtorqued by factory, dealer warranty loostened and readjusted, initial tendency, failure to return to neutral, rough bearing feeling, caused many near misses with vehicles ahead, problem unresolved, I can feel it, dealer can not. Contra Costa Powersports, 1150 Concord Ave Ste 100, Concord, CA 94520 (925) 687-7742. Issue regarding drive train, false neutral. Potentially hazardous conditions occurred three times. Pulled over to adjust GPS, engine running, shifted to neutral, neutral light illuminated on dash, put the side stand down,, released the clutch bike still in gear, bike lunged forward, off of sidestand, bike headed for ground with rider, lucky first two times I had my hand on the front brake, lock up brake preventing bike from launching off the side stand and crashing to ground. First time with stock clutch and brake levers set up by dealer with 1/16 clutch free play, third time with Warp9 aftermarket adjustable brake and clutch levers, was in same 1/16" free play when set up, cable seated during 100 mile ride, gap then 1/4", third false neutral, dash displayed green neutral indication light, side stand down, released clutch, bike still in gear, this time hand not on brake lever, didn't anticipate bike movement, the bike launched forward off the sidestand, tried to eject me into the roadway. Could have been lethal consequences had I not recovered the bike before it dropped to the roadway, I just managed to get it back up and out of the roadway before cars came around the blind mountain turn. The Clutch lever being slightly out of adjustment had no impact on shifting gears, and didn't miss one gear change. Stock clutch lever or Warp9 aftermarket, clutch freeplay 1/16 to 1/4 made no difference. I can not replicate the hazard, it occurred randomly. Technically, weather the neutral light illuminates on the dash or not, in gear, deploying the side stand should kill the bike. Dealer can not duplicate what to we do now?