2002 Kawasaki KLR650 Engine cooling Problems

“I own a 2002 Kawasaki KLR650 with approximately 9500 miles on it. I was riding at low speed on the date below when I heard a loud metal clang in the engine and the motorcycle came to a screeching halt. Luckily, I was only traveling at 30 MPH and I was not in traffic. The cause of the incident was not immediately known. …”

“Balancer tensioner spring failed. I had read reports on the internet desctibing the balancer tensioner system as being prone to failure. I found that the tensioner spring had broken where it attaches to the engine case. The motorcycle has 6706 miles on it. I am replacing the spring and tension adjuster with an improved aftermarket kit. The failure was found before there was any major damage to the engine.”

“The balancer idler shaft tensioning sprong was discovered to be broken when preventive maintenance was carried out on my 2002 Kawasaki klr 650 motorcycle at 2867 miles. Potentially, this failure could have caused the engine to sieze whilst in operation.”

“Subject: 2002 Kawasaki KLR650. November 2003, 16,500+ miles: davis service center, montrose, colorado, was asked to replace the stock counterbalancer chain tensioner lever with a stainless steel upgrade from eagle manufacturing & engineering. This was to be preventive maintenance since I've heard from that this is a weak point. Upon internal inspection, the stock counter balanced chain tensioner lever was found to be broken. A broken piece had gotten into the transmission main shaft bearing and destroyed the race/bearing-holder. …”

“Kawasaki KLR650's have a problem with an engine balancer lever breaking. I have a 2002 klr and found my lever to be broken in three places. Although it did not cause a crash in this case, the broken pieces could easily cause an accident (and have in the past). You certainly do not want this piece to break while you on the high way. It is well known that new klr owners change this part out with an after market part to avoid injury.”