4 recalls across 2 model years
The Kawasaki KLR650 has 4 recalls covering 2002 and 2008 model years, with the most serious being a muffler that can separate from 2008 models while riding, turning into a road hazard and raising the risk of a crash. The 2008 model year accounts for three of the four recalls. Beyond the muffler separation risk, the main wiring harness on 2008 models can chafe against the frame and cause the engine to stall unexpectedly, leaving the rider without power in traffic. Also on 2008 models, the turn signal stalks can break and leave the rider unable to clearly signal a turn, creating a collision risk in traffic.
Going back to the 2002 model year, there is a similar muffler concern: mounting bolts that were not tightened sufficiently during assembly can work loose, allowing the muffler to detach and strike nearby people or objects.
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