2006 Kawasaki KL650A6F

UPON DETAILED INTERNAL INSPECTION OF ENGINE, IT WAS DETERMINED THAT THE BALANCER CHAIN TENSIONING ASSEMBLY HAD FAILED. EVIDENCE SHOWED THAT THE SPRING (POORLY MADE) HAD BEEN BROKEN FOR QUITE SOME TIME. IT WAS ALSO EVIDENT THAT HAD THE SPRING NOT BROKEN, THE VERY POORLY MADE TENSIONER QUADRANT WOULD HAVE BROKEN INSTEAD LEADING TO CATASTROPHIC ENGINE DAMAGE AND MOST LIKELY A CRASH AT THE TIME OF ENGINE FAILURE. THE FACTORY PARTS WERE REPLACED WITH UPGRADED AFTERMARKET PARTS. *TR

2006 KAWASAKI KLR650 MOTORCYCLE. BALANCER CHAIN TENSIONER COMMONLY REFERRED TO AS THE KLR650 "DOOHICKIE". COASTING DOWN A SLEIGHT GRADE WITH MOTORCYCLE IN GEAR, MOTOR SUDDENLY MADE RAPPING NOISE AND STOPPED. UPON INVESTIGATION, IT WAS DETERMINED THAT THE SPRING KEEPING TENSION ON THE "DOOHICKIE" HAD FAILED, GOT CAUGHT IN THE TIMING CHAIN WHICH IN TURN BENT BOTH INTAKE VALVES. THE BALANCER CHAIN TENSIONER IS A VERY COMMON PROBLEM WITH KLR650'S SINCE THEIR FIRST INTRODUCTION. REPLACED INTAKE VALVES, BALANCER CHAIN TENSIONER, HEAD GASKET, ENGINE SIDE COVER GASKETS, OIL AND ANTIFREEZE. COST $200+. *TR

TL*THE CONTACT OWNS A 2006 KAWASAKI KLR650 (NA). WHILE PERFORMING MAINTENANCE ON THE VEHICLE, THE CONTACT NOTICED THAT THE IDLER SHAFT SPRING FAILED. THE CONTACT REMOVED A PIECE OF THE IDLER SHAFT SPRING FROM THE ENGINE. THE DEALER WAS NOTIFIED. THE CONTACT WILL BE REPAIRING THE VEHICLE. THE FUEL SYSTEM AND FAILURE MILEAGE WERE UNKNOWN. THE CURRENT MILEAGE WAS 13,300. UPDATED 11/15/07 *TR

AFTER READING ABOUT OTHERS THAT HAD THIS DEFECTIVE PART ON THE EXACT SAME MOTORCYCLE AS I HAVE I DECIDED TO REPLACE THE PART WITH A AFTERMARKET UPGRADE. WHEN I OPENED MY ENGINE CASE I NOTICED THAT PART OF IT WAS ALREADY BROKEN! I HAVE UNDER 3000 MILES ON THE MOTORCYCLE. THE PART THAT I REPLACED WAS COUNTERBALANCED TENSIONER AND SPRING. THE SPRING WA S ALREADY BROKEN, AND PART OF IT WENT INTO THE ENGINE. *AK

THE COUNTER BALANCER ADJUSTMENT LEVER SPRING ON MY 2006 KAWASAKI KLR650 W/ 1700 MILES FAILED. ALTHOUGH NO DAMAGE OR INJURY WAS CAUSED IN THIS CASE, THE POSSIBILITY OF DAMAGE AND INJURY TO OTHER USERS OF THIS MODEL MOTORCYCLE EXISTS DUE TO FRAGMENTED PARTS FROM THE BROKEN ITEMS CIRCULATING THROUGH THE ENGINE AND CAUSING AN ENGINE SEIZURE. THIS IS A COMMON PROBLEM ON ALL KLR MODELS. KAWASAKI HAS BEEN ADVISED OF THE PROBLEM BY LETTER DATED APRIL 18 2006, DENIES THE PROBLEM, AND REFUSES TO REPLACE THE FAULTY COMPONENTS IN THIS OR ANY OTHER KLR. THEY REFUSED A WARRANTY CLAIM AND THE REPAIR WORK WAS PAID FOR BY ME. I RETAINED THE BROKEN PART. *NM