2003 Kawasaki KLR650 Engine cooling Problems
- Complaints
- 5about this part
- Share
- 83%of 6 total for the year
- Median mileage
- 10,265miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 5 complaints about the engine cooling of the 2003 Kawasaki KLR650, 83% of the 6 complaints for this model year. Where a mileage was given, the median is 10,265 miles.
Fewer than 15 complaints name this part, so treat the figures as a rough indication only.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“I just checked my idler shaft lever (doohickey) on my 2003 klr 650. The doohickey was intact but, the spring was broke. I can't find the end of the spring that broke off and the chain wore part way through the spring leaving metal shavings throughout the engine not good!!! Just ordered new doohickey and spring from arrowhead motorsports.”
NHTSA complaint #10147202, filed 2006-01, 8,900 miles“I have a 2003 Kawasaki KLR650 and the balancer lever adjuster is broken. It makes a loud noise and there is a possibility of engine seizure. I have done nothing to fix this yet and am driving an alternate vehicle.”
NHTSA complaint #10197781, filed 2007-07, 2,200 miles“Klr650 engine idle lever adjuster spring failed sending metal fragments through out the engine that I had to fish out - very very common problem to the point that it is the first thing people do when they buy a klr of any year.”
NHTSA complaint #10358886, filed 2010-10, 15,000 miles“Kawasaki klr 650 motorcycle chain tensioner counter balancer and retainer spring broken and missing. The broken pieces can cause catastrophic failure including engine seizure while in operation. Replaced the parts from aftermarket supplier.”
NHTSA complaint #10266451, filed 2009-04, 25,600 miles“The motorcycle cam chain adjuster spring broke and caused the vehicle to stall while driving. Sausage, klr 650, 2003. While driving consumer heard a grinding sound from the left side of the engine. The broken spring bent the intake valve and damaged valve guides (sausage 630 2003).”
NHTSA complaint #10038446, filed 2003-10, 10,265 milesEngine cooling: other model years
Other parts of the 2003 Kawasaki KLR650
← All problems reported for the 2003 Kawasaki KLR650
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology