Explore the records behind recurring owner reports.
6 owner complaints analyzed
0 distinct recall campaigns
10,265 mi median reported failure mileage
Scope: 2003 model year. Data updated: . 5 complaints include usable failure mileage. View data status.
This selection has limited data. It remains available for lookup but is excluded from search indexing.
Engine And Engine Cooling is the most frequently named component, appearing in 3 of 6 complaints (50.0%). A complaint can name multiple components.
| Topic | Matching reports | Share of complaints |
|---|---|---|
| Engine operation | 1 | 16.7% |
Topic matches use published keyword rules. They describe mentions, including negations or comparisons, and do not confirm a diagnosis. Read the matching rules.
Number of unique complaints naming each component. Top eight shown.
| Category | Count |
|---|---|
| Engine And Engine Cooling | 3 |
| Engine And Engine Cooling:Engine | 2 |
| Steering | 1 |
| Tires | 1 |
Engine And Engine Cooling: 3; Engine And Engine Cooling:Engine: 2; Steering: 1; Tires: 1
Complaint counts in mileage bands. These are not failure rates per vehicle or mile.
| Category | Count |
|---|---|
| Under 25,000 | 4 |
| 25,000 to 49,999 | 1 |
| 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: 4; 25,000 to 49,999: 1; 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 (4). 1 complaints have missing, zero or invalid mileage.
Year the complaint was filed, not the vehicle model year or incident year. The snapshot year is partial.
| Category | Count |
|---|---|
| 2003 | 1 |
| 2004 | 1 |
| 2006 | 1 |
| 2007 | 1 |
| 2009 | 1 |
| 2010 | 1 |
2003: 1; 2004: 1; 2006: 1; 2007: 1; 2009: 1; 2010: 1
Engine And Engine Cooling leads the component reports. Engine operation 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 provide context, not a representative sample or a verified diagnosis.
THE MOTORCYCLE CAM CHAIN ADJUSTER SPRING BROKE AND CAUSED THE VEHICLE TO STALL WHILE DRIVING. SAUSAGE, KLR 650, 2003. *AK WHILE DRIVING CONSUMER HEARD A GRINDING SOUND FROM THE LEFT SIDE OF THE ENGINE. THE BROKEN SPRING BENT THE INTAKE VALVE AND DAMAGED VALVE GUIDES (SAUSAGE 630 2003). *TS *NLM
Owner-reported narrative. 10,265 miles reported. Look up ODI 10038446 at NHTSA ↗
WHEN THE MOTORCYCLE WAS TAKEN OUT OF STORAGE CONSUMER NOTICED THAT TIRES SIDEWALL DEVELOPED WEATHER CHECKS. THESE WERE SMALL CRACKS THAT WENT AROUND THE SIDEWALL OF THE TIRES. THE MOTORCYCLE WAS DRIVEN FOR 6 MONTHS, THEN STORED FOR 6 MONTHS PRIOR TO THIS PROBLEM OCCURRING. DEALERSHIP WAS CONTACTED BUT COULD NOT IDENTIFY WHAT CAUSED THE CRACKS TO OCCUR BECAUSE THE MOTORCYCLE WASN'T STORED NEXT TO ANY CHEMICALS. THE FRONT TIRE SIZE WAS 90/90-21 AND THE REAR TIRE SIZE WAS 130/80-17. THE MODEL NAME LISTED ON TIRE WAS K750.*AK
Owner-reported narrative. Look up ODI 10081619 at NHTSA ↗
I JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKEY AND SPRING FROM ARROWHEAD MOTORSPORTS. *JB
Owner-reported narrative. 8,900 miles reported. Look up ODI 10147202 at NHTSA ↗
I HAVE A 2003 KAWASAKI KLR650 AND THE BALANCER LEVER ADJUSTER IS BROKEN. IT MAKES A LOUD NOISE AND THERE IS A POSSIBILITY OF ENGINE SEIZURE. I HAVE DONE NOTHING TO FIX THIS YET AND AM DRIVING AN ALTERNATE VEHICLE. *JB
Owner-reported narrative. 2,200 miles reported. Look up ODI 10197781 at NHTSA ↗
KAWASAKI KLR 650 MOTORCYCLE CHAIN TENSIONER COUNTER BALANCER AND RETAINER SPRING BROKEN AND MISSING. THE BROKEN PIECES CAN CAUSE CATASTROPHIC FAILURE INCLUDING ENGINE SEIZURE WHILE IN OPERATION. REPLACED THE PARTS FROM AFTERMARKET SUPPLIER. *TR
Owner-reported narrative. 25,600 miles reported. Look up ODI 10266451 at NHTSA ↗
KLR650 ENGINE IDLE LEVER ADJUSTER SPRING FAILED SENDING METAL FRAGMENTS THROUGH OUT THE ENGINE THAT I HAD TO FISH OUT - VERY VERY COMMON PROBLEM TO THE POINT THAT IT IS THE FIRST THING PEOPLE DO WHEN THEY BUY A KLR OF ANY YEAR. *TR
Owner-reported narrative. 15,000 miles reported. Look up ODI 10358886 at NHTSA ↗
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.
Inspect model-year patterns, reported mileage, monthly activity and the evidence behind each signal.
6 unique complaints in this selection. Analysis snapshot: 2026-10-01.
Missing, zero and invalid mileage is excluded. Dates after the snapshot are excluded. Examples are limited selections, not a representative sample.
Model-wide comparison of the eight most reported components across the model. Cells show counts and shares within each model year. Open a cell for source examples.
| Component | 2017 | 2022 | 2023 | 2024 |
|---|---|---|---|---|
| Exterior Lighting | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Engine And Engine Cooling:Engine | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Engine And Engine Cooling | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Steering | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 1487.5%ODI 11535256Motorcycle with ML serial numbers have been overtorqued steering bearing nuts from factory, multiple problems showing up. Steering on mine locked up in a turn, but was able to force it to straighten out. Kawasaki is aware they overtorqued (via multiple sources) but has not released a tech bulletin, or service recall on a dangerous situation. Slow speeds steering will have a tight bind at the 12" position, and will have a hard time turning left or right out of the tight spot. Occasionally, turning back into the 12 position will cause a bind/catc… | 00.0%No examples available for this selection. |
| Engine | 00.0%No examples available for this selection. | 1100.0%ODI 11481956After driving for 1.5 hours the engine will not start. There's less than 600 miles driven. | 16.3%ODI 11582029Steering 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 [phone removed]. 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 st… | 1100.0%ODI 11694562 · 86,000 miThe contact owns a 2024 Kawasaki KLR650. The contact stated that while riding approximately 2-3 MPH, the ABS engaged independently. The contact stated that there was an ABS module failure as well. No warning light was illuminated. The contact stated that the motorcycle downshifted unexpectedly without the clutch being activated. An independent mechanic was contacted. The contact exited the motorcycle and walked the motorcycle to the closest shop. The motorcycle was taken to an independent mechanic, where it was diagnosed, and determined that t… |
| Electrical System | 00.0%No examples available for this selection. | 1100.0%ODI 11481956After driving for 1.5 hours the engine will not start. There's less than 600 miles driven. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Structure | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
| Engine And Engine Cooling:Engine:Gasoline | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. | 00.0%No examples available for this selection. |
Darker cells indicate a larger share of submitted complaints. Components overlap. This measures complaint composition, not failure probability.
Median and middle 50% of usable owner-reported mileages. Ranges require at least five records.
| Component | Mileage range (25th–75th percentile) | Median | Usable records | Examples |
|---|---|---|---|---|
| Engine And Engine Cooling | Too few reports for a range | 8,900 mi | 3 (sparse) | ODI 10147202 · 8,900 miI JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKEY AND SPRING FROM ARROWHEAD MOTORSPORTS. *JB ODI 10197781 · 2,200 miI HAVE A 2003 KAWASAKI KLR650 AND THE BALANCER LEVER ADJUSTER IS BROKEN. IT MAKES A LOUD NOISE AND THERE IS A POSSIBILITY OF ENGINE SEIZURE. I HAVE DONE NOTHING TO FIX THIS YET AND AM DRIVING AN ALTERNATE VEHICLE. *JB ODI 10266451 · 25,600 miKAWASAKI KLR 650 MOTORCYCLE CHAIN TENSIONER COUNTER BALANCER AND RETAINER SPRING BROKEN AND MISSING. THE BROKEN PIECES CAN CAUSE CATASTROPHIC FAILURE INCLUDING ENGINE SEIZURE WHILE IN OPERATION. REPLACED THE PARTS FROM AFTERMARKET SUPPLIER. *TR |
| Engine And Engine Cooling:Engine | Too few reports for a range | 12,633 mi | 2 (sparse) | ODI 10038446 · 10,265 miTHE MOTORCYCLE CAM CHAIN ADJUSTER SPRING BROKE AND CAUSED THE VEHICLE TO STALL WHILE DRIVING. SAUSAGE, KLR 650, 2003. *AK WHILE DRIVING CONSUMER HEARD A GRINDING SOUND FROM THE LEFT SIDE OF THE ENGINE. THE BROKEN SPRING BENT THE INTAKE VALVE AND DAMAGED VALVE GUIDES (SAUSAGE 630 2003). *TS *NLM ODI 10358886 · 15,000 miKLR650 ENGINE IDLE LEVER ADJUSTER SPRING FAILED SENDING METAL FRAGMENTS THROUGH OUT THE ENGINE THAT I HAD TO FISH OUT - VERY VERY COMMON PROBLEM TO THE POINT THAT IT IS THE FIRST THING PEOPLE DO WHEN THEY BUY A KLR OF ANY YEAR. *TR |
| Steering | Too few reports for a range | 8,900 mi | 1 (sparse) | ODI 10147202 · 8,900 miI JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKEY AND SPRING FROM ARROWHEAD MOTORSPORTS. *JB |
Explore monthly filing activity alongside recall announcements. Up to ten years of monthly history is available.
Solid line: filed complaints. Dashed amber lines: recall announcement dates for this vehicle selection; markers include all recall components. The latest month is partial. Temporal proximity does not establish causation.
| Month | Complaints | Campaigns announced | Examples |
|---|---|---|---|
| 2024-11 | 0 | None | No examples available for this selection. |
| 2024-12 | 0 | None | No examples available for this selection. |
| 2025-01 | 0 | None | No examples available for this selection. |
| 2025-02 | 0 | None | No examples available for this selection. |
| 2025-03 | 0 | None | No examples available for this selection. |
| 2025-04 | 0 | None | No examples available for this selection. |
| 2025-05 | 0 | None | No examples available for this selection. |
| 2025-06 | 0 | None | No examples available for this selection. |
| 2025-07 | 0 | None | No examples available for this selection. |
| 2025-08 | 0 | None | No examples available for this selection. |
| 2025-09 | 0 | None | No examples available for this selection. |
| 2025-10 | 0 | None | No examples available for this selection. |
| 2025-11 | 0 | None | No examples available for this selection. |
| 2025-12 | 0 | None | No examples available for this selection. |
| 2026-01 | 0 | None | No examples available for this selection. |
| 2026-02 | 0 | None | No examples available for this selection. |
| 2026-03 | 0 | None | No examples available for this selection. |
| 2026-04 | 0 | None | No examples available for this selection. |
| 2026-05 | 0 | None | No examples available for this selection. |
| 2026-06 | 0 | None | No examples available for this selection. |
| 2026-07 | 0 | None | No examples available for this selection. |
| 2026-08 | 0 | None | No examples available for this selection. |
| 2026-09 | 0 | None | No examples available for this selection. |
| 2026-10 (partial) | 0 | None | No examples available for this selection. |
Complete months in the latest six months with at least 10 complaints, at least twice the preceding 12-month average, and at least three square-root deviations above that average.
This is a descriptive screening rule, not a statistical defect finding. Publicity and reporting changes can increase submissions.
No complete months meet the spike thresholds for this selection.
Model-wide cumulative reports during the first three or five calendar years, starting with the model year (age 0). Only fully elapsed windows are compared.
2022: 1 complaints · 2023: 16 complaints
| Model year | Through age 0 | Through age 1 | Through age 2 |
|---|---|---|---|
| 2022 | 1 | 1 | 1 |
| 2023 | 12 | 16 | 16 |
| Year | Incident dates used | Filing date fallbacks | Excluded dates |
|---|---|---|---|
| 2022 | 1 | 0 | 0 |
| 2023 | 16 | 0 | 0 |
Incident date is preferred when valid and no later than filing; otherwise filing date is used. Model year approximates age. Equal observation time does not adjust for sales, distance driven or reporting delays. One complaint linked to multiple model years can appear in each cohort.
Each cell counts unique complaints naming both components. Open a nonzero cell for examples.
| Component | Engine And Engine Cooling | Engine And Engine Cooling:Engine | Steering | Tires |
|---|---|---|---|---|
| Engine And Engine Cooling | — | 0 | 1ODI 10147202 · 8,900 miI JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKEY AND SPRING FROM ARROWHEAD MOTORSPORTS. *JB | 0 |
| Engine And Engine Cooling:Engine | 0 | — | 0 | 0 |
| Steering | 1ODI 10147202 · 8,900 miI JUST CHECKED MY IDLER SHAFT LEVER (DOOHICKEY) ON MY 2003 KLR 650. THE DOOHICKEY WAS INTACT BUT, THE SPRING WAS BROKE. I CAN'T FIND THE END OF THE SPRING THAT BROKE OFF AND THE CHAIN WORE PART WAY THROUGH THE SPRING LEAVING METAL SHAVINGS THROUGHOUT THE ENGINE NOT GOOD!!! JUST ORDERED NEW DOOHICKEY AND SPRING FROM ARROWHEAD MOTORSPORTS. *JB | 0 | — | 0 |
| Tires | 0 | 0 | 0 | — |
Co-reporting does not establish that one component caused another concern.
Specific keyword mentions beyond broad component labels. Matching includes negations and comparisons and does not confirm a diagnosis.
1 patterns with matching reports.
1 mentions · 16.7% of complaints
Median mileage: 10,265 mi (1 usable records).
THE MOTORCYCLE CAM CHAIN ADJUSTER SPRING BROKE AND CAUSED THE VEHICLE TO STALL WHILE DRIVING. SAUSAGE, KLR 650, 2003. *AK WHILE DRIVING CONSUMER HEARD A GRINDING SOUND FROM THE LEFT SIDE OF THE ENGINE. THE BROKEN SPRING BENT THE INTAKE VALVE AND DAMAGED VALVE GUIDES (SAUSAGE 630 2003). *TS *NLM
\b(stall\w*|loss of power|lost power|engine shut\w* off)\b