The Kawasaki KLR650, a legendary dual-sport motorcycle, has earned a reputation for its rugged reliability and go-anywhere capability. However, even this iconic machine isn't without its quirks and potential issues. Understanding these common problems can help you keep your KLR running smoothly, whether you're tackling a transcontinental adventure or just commuting to work. Let's dive into the most frequent concerns KLR650 owners face.
The Dreaded "Doohickey": A KLR650 Right of Passage?
The "doohickey," officially known as the balancer chain adjuster lever, is arguably the most notorious KLR650 problem. It's a small, inexpensive part responsible for maintaining proper tension on the balancer chain, which reduces engine vibrations. The factory doohickey is often made of a weak material and prone to failure, especially in older models.
Why is this a big deal? A broken doohickey can lead to a loose balancer chain, causing excessive engine vibration and, in the worst-case scenario, engine damage. This can range from irritating noise to complete engine seizure.
What's the fix? The solution is simple: replace the stock doohickey with an aftermarket version made of stronger material, usually steel. Several reputable manufacturers offer these upgraded doohickeys, along with the necessary tools for installation. This is often considered a preventative measure, even if your original doohickey hasn't failed yet. Consider it cheap insurance for your KLR's longevity.
When should I replace it? Many KLR owners recommend replacing the doohickey during the first major service, typically around 5,000 miles. However, some choose to do it sooner for peace of mind, especially on older models.
Oil Consumption: Keeping an Eye on Levels
Oil consumption is another common concern, particularly in KLR650s from the 2008-2018 generation (Gen 2). While some oil consumption is normal in any engine, excessive oil consumption in the KLR650 can indicate a more serious issue.
What causes it? Several factors can contribute to oil consumption, including worn piston rings, valve stem seals, or cylinder bore damage. In the Gen 2 models, the factory piston ring design was identified as a significant contributor, leading to increased oil usage.
How do I know if it's a problem? Regularly check your oil level using the sight glass (or dipstick on older models). If you find yourself adding oil frequently, more than a quart every 1,000 miles, it's a sign that something isn't right. Keep a log of your oil consumption to track any changes.
What can I do about it? The best course of action depends on the severity of the problem. A top-end rebuild, including replacing the piston and rings with an updated design (often from a different manufacturer like Wiseco), is the most effective solution for significant oil consumption. For minor oil consumption, using a slightly thicker oil or adding an oil stabilizer might help, but these are temporary fixes.
Cooling System Quirks: Staying Cool Under Pressure
The KLR650's cooling system is generally reliable, but it's not immune to problems. Overheating, coolant leaks, and radiator damage are issues that can crop up, especially during demanding off-road riding or in hot climates.
What are the common culprits? Leaks can occur at hose connections, the water pump, or even the radiator itself. A clogged radiator, either internally or externally with mud and debris, can also restrict coolant flow and lead to overheating. Additionally, a faulty thermostat or a failing radiator fan can contribute to cooling issues.
How can I prevent problems? Regular maintenance is key. Inspect hoses for cracks and replace them as needed. Flush and replace the coolant every two years. Clean the radiator fins regularly to remove dirt and debris. Ensure the radiator fan is functioning correctly.
What if I'm already having problems? Start by checking the coolant level and looking for leaks. If you suspect a clogged radiator, try flushing it with a garden hose. If the problem persists, consider replacing the thermostat or water pump. For serious overheating, it's best to consult a qualified mechanic.
Electrical Gremlins: When Things Go Dark
While the KLR650 is known for its simplicity, the electrical system can sometimes present challenges. Common issues include blown fuses, faulty wiring, and problems with the charging system.
What are the typical electrical issues? Blown fuses are often caused by short circuits or overloaded circuits. Wiring can become damaged over time due to vibration, abrasion, or exposure to the elements. The charging system, including the stator, regulator/rectifier, and battery, can also fail, leading to a dead battery or dim lights.
How can I troubleshoot electrical problems? Start by checking the fuses. If a fuse keeps blowing, there's likely a short circuit somewhere. Inspect the wiring harness for any obvious damage, such as frayed wires or loose connections. Use a multimeter to test the battery voltage and the charging system output.
What are some preventative measures? Ensure all electrical connections are clean and secure. Use dielectric grease on connections to prevent corrosion. Consider upgrading the wiring harness with a heavier gauge wire to improve reliability. Regularly check the battery terminals for corrosion and clean them as needed.
Suspension Woes: Bumps in the Road
The KLR650's stock suspension is often criticized for being soft and underdamped, especially for aggressive off-road riding or carrying heavy loads. This can lead to a bouncy ride, poor handling, and bottoming out on rough terrain.
What are the limitations of the stock suspension? The front forks are often too soft and lack adjustability. The rear shock is also underdamped and can struggle to control the bike's movement over bumps.
How can I improve the suspension? Several upgrades are available to improve the KLR650's suspension. For the front forks, you can install stiffer springs, add fork emulators or cartridge kits, or even swap in a complete set of aftermarket forks. For the rear shock, you can replace it with an aftermarket shock that offers adjustable damping and preload.
What's the best option for me? The best suspension upgrade depends on your riding style and budget. Stiffer springs are a relatively inexpensive option that can significantly improve the handling. Fork emulators or cartridge kits offer more sophisticated damping control. A high-quality aftermarket rear shock is a worthwhile investment for serious off-road riders.
Fuel System Foibles: Keeping the Engine Fed
The KLR650's carburetor is generally reliable, but it can be susceptible to problems caused by dirty fuel, clogged jets, or worn components. These issues can lead to poor starting, rough idling, and reduced performance.
What are the common carburetor problems? Dirty fuel can clog the jets and passages in the carburetor, restricting fuel flow. Worn needles and seats can cause fuel leaks and flooding. The diaphragm can also crack or tear, affecting the carburetor's ability to regulate fuel mixture.
How can I prevent carburetor problems? Use high-quality fuel and add a fuel stabilizer to prevent the formation of deposits. Clean the carburetor regularly, especially if the bike sits for extended periods. Replace worn components as needed.
What if I'm having carburetor problems? Start by cleaning the carburetor thoroughly. If the problem persists, inspect the jets, needles, and diaphragm for wear or damage. Consider rebuilding the carburetor with a rebuild kit.
Frame Cracks: A Sign of Stress
While not extremely common, some KLR650 owners have reported frame cracks, particularly around the subframe mounting points or the swingarm pivot. These cracks are usually caused by excessive stress, such as carrying heavy loads, aggressive off-road riding, or accidents.
Why is this a serious issue? Frame cracks can compromise the bike's structural integrity and lead to dangerous handling.
How can I prevent frame cracks? Avoid overloading the bike, especially the rear subframe. Reinforce the subframe mounting points if you plan to carry heavy loads. Inspect the frame regularly for cracks, especially after off-road riding or accidents.
What if I find a frame crack? Have the crack professionally repaired by a qualified welder. Reinforce the repaired area to prevent future cracks.
Frequently Asked Questions
- What is the "doohickey," and why is it important? The doohickey is the balancer chain adjuster lever. The stock one is weak and prone to failure, potentially damaging the engine.
- Why does my KLR650 burn oil? Gen 2 KLR650s (2008-2018) are known for oil consumption due to the factory piston ring design. Replacing the piston and rings often solves the problem.
- How often should I change the oil in my KLR650? Change the oil every 3,000-5,000 miles, depending on riding conditions. Shorter intervals are recommended for dusty or off-road riding.
- My KLR650 is overheating. What should I do? Check the coolant level, look for leaks, and clean the radiator fins. Ensure the radiator fan is working correctly.
- What are some common KLR650 modifications? Popular modifications include replacing the doohickey, upgrading the suspension, adding crash bars, and installing a larger windscreen.
Conclusion
The Kawasaki KLR650, despite its few known issues, remains a remarkably capable and versatile motorcycle. Understanding and addressing these common problems proactively will help you keep your KLR running strong for years to come, allowing you to fully enjoy its legendary reliability and adventure-ready spirit.