Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 2 of 3 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
Engine And Engine Cooling. Review the 2 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Service Brakes, Hydraulic. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Structure. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
1 crash reports0 fire reports0 injury reports
What owners actually said
3 reports
4,936 miles · Dec 22, 2004
Engine And Engine Cooling
2004 KAWASAKI KLR650 1) VEHICLE WAS PURCHASED NEW AND RIDDEN ACCORDING TO BREAK-IN SCHEDULE. THE VEHICLE WAS RIDDEN MOSTLY ON THE SURFACE STREETS AND HIGHWAYS, AND ABOUT 100 MILES OFF-ROAD. THE BOLT,IDLER LEVER PN 92150-1923 WAS ADJUSTED AT THE INTERVAL RECOMMENDED BY THE MANUAL. 2) AT 4,932 MILES, THE SPRING,IDLER SHAFT, PN 9…
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2004 KAWASAKI KLR650 1) VEHICLE WAS PURCHASED NEW AND RIDDEN ACCORDING TO BREAK-IN SCHEDULE. THE VEHICLE WAS RIDDEN MOSTLY ON THE SURFACE STREETS AND HIGHWAYS, AND ABOUT 100 MILES OFF-ROAD. THE BOLT,IDLER LEVER PN 92150-1923 WAS ADJUSTED AT THE INTERVAL RECOMMENDED BY THE MANUAL. 2) AT 4,932 MILES, THE SPRING,IDLER SHAFT, PN 92144-1860 IS MISSING. IT MAY BE IN THE ENGINE, OR MAY NOT HAVE BEEN INSTALLED AT THE FACTORY. THIS MAKES IT IMPOSSIBLE TO ADJUST BALANCER CHAIN TENSION WITHOUT DISASSEMBLING THE ENGINE. A LOOSE BALANCER CHAIN CAN CAUSE CATASTROPHIC ENGINE FAILURE. 3) NO REPAIR HAS BEEN MADE YET. THE SPRING MAY BE IN THE ENGINE. *JB
NHTSA ODI #10104323
300 miles · Sep 10, 2004
Engine And Engine Cooling
MOTOR WAS DEFECTIVE. CONSUMER HAD THE MOTORCYCLE FOR 1 WEEK AND EXPERIENCED AN ENGINE PROBLEM. IT MADE A KNOCKING NOISE THAT SOUNDED LIKE A ROD WAS DEFECTIVE WITHIN THE ENGINE. THIS NOISE OCCURRED WHEN THE MOTORCYCLE WAS STARTED AND CONTINUED. CONSUMER TOOK THE MOTORCYCLE TO THE DEALER WHERE THE MOTORCYCLE WAS PURCHASED AND CON…
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MOTOR WAS DEFECTIVE. CONSUMER HAD THE MOTORCYCLE FOR 1 WEEK AND EXPERIENCED AN ENGINE PROBLEM. IT MADE A KNOCKING NOISE THAT SOUNDED LIKE A ROD WAS DEFECTIVE WITHIN THE ENGINE. THIS NOISE OCCURRED WHEN THE MOTORCYCLE WAS STARTED AND CONTINUED. CONSUMER TOOK THE MOTORCYCLE TO THE DEALER WHERE THE MOTORCYCLE WAS PURCHASED AND CONTACTED THE MANUFACTURER, WHO WOULD NOT AUTHORIZE THE DEALER TO GO INTO THE CRANK CASE TO INVESTIGATE THE DEFECT. MANUFACTURER'S SOLUTION WAS FOR THE DEALERSHIP TO GIVE THE MOTORCYCLE BACK TO CONSUMER BECAUSE THE MOTORCYCLE NEEDED TO BE BROKEN IN. CONSUMER WAS DISSATISFIED. *AK
NHTSA ODI #10091801
Mileage unknown · Aug 11, 2004
Service Brakes, HydraulicStructureCrash
WHILE DRIVING 25 MPH AND THE BRAKES WERE APPLIED FOR AN URGENT STOP MOTORCYCLE FLIPPED OVER. ALSO, EXCESSIVE VIBRATION THROUGHOUT THE ENTIRE BODY. THE CONSUMER FOUND OUT THAT THE FRAME WAS STRESSED WHEN THE MOTOR WAS MOUNTED. *AK
NHTSA ODI #10087655
Official recalls
0
No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
0
No exact-year investigations in this snapshot.
2004 Kawasaki Concours Problems, Complaints & Recalls | Skip That Year
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