2002 Kawasaki KLR650: complaints, problems and recalls
Explore the records behind recurring owner reports.
Key facts
11 owner complaints analyzed
0 distinct recall campaigns
3,000 mi median reported failure mileage
Scope: 2002 model year. Data snapshot: . 5 complaints include usable failure mileage.
Most common problems
Engine And Engine Cooling is the most frequently named component, appearing in 5 of 11 complaints (45.5%). A complaint can name multiple components.
| Topic | Matching reports | Share of complaints |
|---|---|---|
| Transmission and shifting | 1 | 9.1% |
Topic matches use published keyword rules. They describe mentions, including negations or comparisons, and do not confirm a diagnosis. Read the matching rules.
Component breakdown
Number of unique complaints naming each component. Top eight shown.
| Category | Count |
|---|---|
| Engine And Engine Cooling | 5 |
| Engine And Engine Cooling:Cooling System | 1 |
| Engine And Engine Cooling:Engine | 1 |
| Engine And Engine Cooling:Engine:Gasoline | 1 |
| Power Train | 1 |
| Suspension | 1 |
| Tires | 1 |
| Visibility:Rearview Mirrors/Devices:Exterior | 1 |
Engine And Engine Cooling: 5; Engine And Engine Cooling:Cooling System: 1; Engine And Engine Cooling:Engine: 1; Engine And Engine Cooling:Engine:Gasoline: 1; Power Train: 1; Suspension: 1; Tires: 1; Visibility:Rearview Mirrors/Devices:Exterior: 1
Reported problems by failure mileage
Complaint counts in mileage bands. These are not failure rates per vehicle or mile.
| Category | Count |
|---|---|
| Under 25,000 | 5 |
| 25,000 to 49,999 | 0 |
| 50,000 to 74,999 | 0 |
| 75,000 to 99,999 | 0 |
| 100,000 to 149,999 | 0 |
| 150,000 and above | 0 |
Under 25,000: 5; 25,000 to 49,999: 0; 50,000 to 74,999: 0; 75,000 to 99,999: 0; 100,000 to 149,999: 0; 150,000 and above: 0
Under 25,000 miles has the most reports with usable mileage (5). 6 complaints have missing, zero or invalid mileage.
Complaints over time
Year the complaint was filed, not the vehicle model year or incident year. The snapshot year is partial.
| Category | Count |
|---|---|
| 2002 | 1 |
| 2003 | 5 |
| 2005 | 2 |
| 2006 | 1 |
| 2007 | 1 |
| 2009 | 1 |
2002: 1; 2003: 5; 2005: 2; 2006: 1; 2007: 1; 2009: 1
Pattern summary
Engine And Engine Cooling leads the component reports. Transmission and shifting appears in 1 complaint narratives. Use these patterns to inspect individual reports and prepare questions for a mechanic.
Calculated from recorded counts. An AI narrative has not been published for this selection.
Examples from the source records
Examples provide context, not a representative sample or a verified diagnosis.
Owner report 10000675 · 2003-01-01 (January 1, 2003)
THE BALANCER IDLER SHAFT TENSIONING SPRONG WAS DISCOVERED TO BE BROKEN WHEN PREVENTIVE MAINTENANCE WAS CARRIED OUT ON MY 2002 KAWASAKI KLR 650 MOTORCYCLE AT 2867 MILES. POTENTIALLY, THIS FAILURE COULD HAVE CAUSED THE ENGINE TO SIEZE WHILST IN OPERATION.
Owner-reported narrative. 2,867 miles reported. Look up ODI 10000675 at NHTSA ↗
Owner report 10011343 · 2003-03-05 (March 5, 2003)
NAR 03/05/2003 AFTER THREE CONSECUTIVE TRIPS TO THE REPAIRS SHOP WITHIN 30 DAYS FOR ENGINE OIL LEAK THE CONSUMER NO LONGER WANTS THE VEHICLE. *CB
Owner-reported narrative. 300 miles reported. Look up ODI 10011343 at NHTSA ↗
Owner report 10026489 · 2003-07-02 (July 2, 2003)
MOTORCYCLE IS UNDER 5000 MILES AND ALREADY HAS CHANGED FRONT AND REAR TIRES. DUNLOP TIRE, MODEL 750, SIZE 130/80-1765S, AND PROBLEM STILLRECURRING, TIRE GOT FLAT.*AK
Owner-reported narrative. Look up ODI 10026489 at NHTSA ↗
Owner report 10041824 · 2003-09-29 (September 29, 2003)
BALANCER IDLE CHAIN ADJUSTER FAILED WHILE DRIVING THE MOTORCYCLE. DEALER NOTIFIED. *AK
Owner-reported narrative. Look up ODI 10041824 at NHTSA ↗
Owner report 10047386 · 2003-11-22 (November 22, 2003)
SUBJECT: 2002 KAWASAKI KLR650. NOVEMBER 2003, 16,500+ MILES: DAVIS SERVICE CENTER, MONTROSE, COLORADO, WAS ASKED TO REPLACE THE STOCK COUNTERBALANCER CHAIN TENSIONER LEVER WITH A STAINLESS STEEL UPGRADE FROM EAGLE MANUFACTURING & ENGINEERING. THIS WAS TO BE PREVENTIVE MAINTENANCE SINCE I'VE HEARD FROM THAT THIS IS A WEAK POINT. UPON INTERNAL INSPECTION, THE STOCK COUNTER BALANCED CHAIN TENSIONER LEVER WAS FOUND TO BE BROKEN. A BROKEN PIECE HAD GOTTEN INTO THE TRANSMISSION MAIN SHAFT BEARING AND DESTROYED THE RACE/BEARING-HOLDER. THE BEARINGS WE…
Owner-reported narrative. 16,500 miles reported. Look up ODI 10047386 at NHTSA ↗
Owner report 10105991 · 2005-01-08 (January 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.*AK
Owner-reported narrative. 3,000 miles reported. Look up ODI 10105991 at NHTSA ↗
Owner report 10144784 · 2005-12-08 (December 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. *AK
Owner-reported narrative. Look up ODI 10144784 at NHTSA ↗
Owner report 10157761 · 2006-05-17 (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. *JB
Owner-reported narrative. Look up ODI 10157761 at NHTSA ↗
Recall history
0 distinct campaigns affect this selection. Announcement dates below are different from vehicle model years. A campaign may cover multiple years.
No recall campaigns are recorded in this snapshot.