The 2005 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 2 complaints with NHTSA, most often about the engine. 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.
“Balancer chain began making noise attempted factory recommended adjustments. Concern was unresolved. Removed stator cover found quadrant and tensioner broken. *tr”
“On the basis of anecdotal information I replaced the stock balancer chain tensioner on my 2005 kawasaki klr 650 motorcycle. These have been known to have problems in this area, and sure enough the spring that is to tension the balance chain as it wears was broken and inoperative. This meant that…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2005 Kawasaki Kl650a as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.