The 2004 Kawasaki Kl650a has 1 NHTSA recall campaign affecting an estimated 33,693 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 1 complaint with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
ON CERTAIN MOTORCYCLES, INSUFFICIENT TIGHTENING OF THE MUFFLER MOUNTING BOLTS COULD ALLOW THE BOLTS TO LOOSEN.
IF THE BOLTS LOOSEN COMPLETELY, IT IS POSSIBLE FOR THE MUFFLER TO SEPARATE FROM THE MOTORCYCLE AND CREATE THE POTENTIAL FOR A CRASH.
DEALERS WILL TIGHTEN TWO MUFFLER MOUNTING BOLTS TO THE PROPER TORQUE FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 22, 2007. OWNERS MAY CONTACT KAWASAKI AT 1-866-802-9381.
Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.
“The balance shaft tenisoner and chain broke on my 2004 klr 650 before I had 10,000 miles on it. *tr”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Kawasaki Kl650a as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.