The 2004 Kawasaki Zx636 B2 has 1 NHTSA recall campaign affecting an estimated 11,018 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 2 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
ON CERTAIN MOTORCYCLES, THE WELDS SECURING THE MUFFLER TO ITS CLAMP COULD FAIL FROM VIBRATION, ALLOWING THE MUFFLER TO SEPARATE FROM THE EXHAUST PIPE.
THIS CAN INCREASE THE RISK OF A CRASH.
DEALERS WILL INSPECT THE MUFFLER AND INSTALL A RUBBER DAMPER. OWNER NOTIFICATION BEGAN ON OCTOBER 20, 2003. OWNERS SHOULD CONTACT KAWASAKI AT 1-866-802-9381.
Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.
“I found a broken idler lever on my 2004 a18 kawasaki klr 650.*ak”
“Exhaust bolt fell off while driving. Muffler fell into the street. Dealer filed a claim with the manufacturer, who stated this was not a manufacturing issue.*ak”
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 Zx636 B2 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.