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 mount bolt issue on 2008 models where vibration and heat can loosen the bolts until the muffler separates from the motorcycle while riding, creating a crash risk. The 2008 model year also has a wiring harness that can chafe against the frame, wearing through the insulation and causing the engine to stall unexpectedly in traffic. There is also a turn signal stalk on 2008 models that can crack and break, leaving the rider unable to signal a turn clearly and raising the risk of a collision. Going back to the 2002 model year, a similar muffler bolt issue exists where insufficient torque applied during assembly can allow the muffler to work loose and detach, becoming a hazard to nearby riders or pedestrians.
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