There are no safety recalls for the 2002 Kawasaki KLR650, but owners have filed 11 complaints with NHTSA.
2002 Kawasaki KLR650 problems reported by owners
| Problem area | Reports | |
|---|
| Engine and Engine Cooling | 8 | |
| Visibility | 1 | |
| Tires | 1 | |
| Suspension | 1 | |
| Power Train | 1 | |
Most reported parts
- Visibility › Rearview Mirrors/Devices › Exterior — 1
- Engine and Engine Cooling › Engine — 1
- Engine and Engine Cooling › Cooling System — 1
- Engine and Engine Cooling › Engine › Gasoline — 1
Typical mileage at the time of the problem: 3,000 miles (median of owner reports).
Problems that are not covered by a recall are paid repairs; labor rates follow local mechanic pay — see what auto mechanics earn in each state.
Recent 2002 Kawasaki KLR650 complaints
Owner reports filed with NHTSA, as written (personal details removed). Complaints are not verified by NHTSA.
Suspension · reported Feb 12, 2009
I have a 2002 kawasaki klr 650 with 6053 miles I AM trying to sell it but no one wants it with out the balancer upgrade aka doohickey. I did mine today and found the spring broken. The tail end was missing. I know alot of people have been affected by this bad part inc. The balancer itself. I don't know what kind of damage the broken spring did but the bike still runs, and with the upgrade from eagle it sound alot better. I think kawasaki own me some $$ for the parts and damage. I doubt if I will ever see any but would like too. Heir could of been a fatal crash when the motor finally jumped…
Engine and Engine Cooling · at 9,000 miles · reported Apr 11, 2007
I own a 2002 kawasaki klr650 with approximately 9500 miles on it. I was riding at low speed on the date below when I heard a loud metal clang in the engine and the motorcycle came to a screeching halt. Luckily, I was only traveling at 30 MPH and I was not in traffic. The cause of the incident was not immediately known. When I brought the motorcycle into the repair shop, I observed after the engine was opened that the idler shaft lever , a welded piece of steel, snapped in half, sending both broken pieces into the lower end of engine, and dislodging the balancer chain from the sprocket, which…
Engine and Engine Cooling · reported May 17, 2006
Kawasaki klr650's have a problem with an engine balancer lever breaking. I have a 2002 klr and found my lever to be broken in three places. Although it did not cause a crash in this case, the broken pieces could easily cause an accident (And have in the past). You certainly do not want this piece to break while you on the high way. It is well known that new klr owners change this part out with an after market part to avoid injury.
Engine and Engine Cooling · reported Dec 8, 2005
Dt: the contact stated the engine counter balance part on motorcycle failed. The contact purchased an after market part and replaced the failed one at his own expense. The motorcycle was not seen by a dealer.
Engine and Engine Cooling · at 3,000 miles · reported Jan 8, 2005
Balancer tensioner spring failed. I had read reports on the internet desctibing the balancer tensioner system as being prone to failure. I found that the tensioner spring had broken where it attaches to the engine case. The motorcycle has 6706 miles on it. I AM replacing the spring and tension adjuster with an improved aftermarket kit. The failure was found before there was any major damage to the engine.
Frequently asked questions
Does the 2002 Kawasaki KLR650 have any recalls?
No. NHTSA has no safety recalls for the 2002 Kawasaki KLR650 as of this update. Check your VIN at nhtsa.gov/recalls for the latest status.
What is the most common problem with the 2002 Kawasaki KLR650?
Owners report engine and engine cooling problems most often (8 reports), followed by visibility (1). The typical mileage when problems were reported is about 3,000 miles.
Are Kawasaki recall repairs free?
Yes. Safety recall repairs are free at authorized Kawasaki dealers, whether you are the first owner or bought the car used.