2008 Kawasaki KLR650 Problems

What owners report

Owners of the 2008 KLR650 most often describe turn signals breaking away from their rubber mounts, frequently within the first couple thousand miles and sometimes while the bike was parked. A smaller group reports a rear shock preload adjuster that fails when they try to set it for a passenger or luggage, and a few describe rubber parts elsewhere, such as windshield well nuts and boots, drying out and crumbling early.

1. 1
   Exterior lighting

   Turn signals break off at rubber mounts

   • 76 complaints (66%)
   • median 2,100 mi at 0.8 yrs old (74 state mileage)
   • filed 2008–2018

   Owners describe turn signals hanging by their wires after the rubber stalk or boot tears or crumbles, often on bikes that were never dropped or bumped. Several say the signal struck the exhaust and melted, and some note the indicator still worked but had nothing holding it on. Dealers replaced the signals under warranty in many cases, sometimes after backorder waits; other owners say the dealer charged them or declined coverage, and some switched to aftermarket signals. Most reports come in under about 5,000 miles, many within the first months of ownership and after normal street riding, with some noting indoor or covered storage.

   What to check: Inspect all four turn signals for cracked, soft or crumbling rubber at the stalk, and gently flex each one. Ask whether any signals were replaced and whether they were OEM or aftermarket parts.

   2 excerpts from owner complaints in NHTSA records

   “The rubber mounting brackets on my 2008 Kawasaki klr 650 turn signals continue to tear loose from the frame. I replaced the first two myself, but when the third one tore in less than three weeks, I brought it to the dealer who ordered me a new one under warranty. The motorcycle was not taken off-road, and is still in the break-in period with 454 miles on it.”

   NHTSA complaint #10235830, filed 2008-07, 350 miles

   “I have a 2008 Kawasaki KLR650, both rear blinker rubber mounts broke and the blinkers were just hanging by the wires when I got home. I am assuming that the rubber used becomes brittle and breaks from vibration. The bike only has 800 miles on it and is a little over a year old. This is a factory defect that others have reported as well.”

   NHTSA complaint #10238603, filed 2008-08, 800 miles
2. 2
   Body and structure

   Other rubber parts dry out and crumble

   Mentioned in 7 of 60 sampled complaints

   Owners describe rubber well nuts holding the windshield to the fairing, plus other grommets and boots, drying out and crumbling on bikes only a year or two old, including ones parked inside. Some say the windshield could come loose, and one mentions the rubber boot on the starter terminal deteriorating. Complaints generally tie these to the same aging seen on the turn signal mounts. Reported on low-mileage bikes, often under about 5,000 miles and within the first year or two, even with garage or covered storage.

   1 related service bulletin

   What to check: Check the rubber well nuts around the windshield and any visible grommets or boots for cracks and missing material, and confirm the windshield is firmly attached.

   2 excerpts from owner complaints in NHTSA records

   “Certain rubber components on the motorcycle have dried out and are crumbling. The following are examples a) turn signal stalks have fallen off without prior notice which could cause an accident due to the other traffic not seeing your turn signal b) windshield retaining well nuts have crumbled and the windshield could come loose or off at hwy speeds causing injury to the driver and possible accident c) rubber boot on the positive terminal of the starter has dryrotted and is crumbling. …”

   NHTSA complaint #10235076, filed 2008-07, 5,500 miles

   “Rotting rubber parts on 2008 Kawasaki KLR650. The grommet fasteners (wellnuts) that attach the windshield to the fairing are dry rotting. This motorcycle was manufactured in 2007 and rubber parts are already deteriorating. This motorcycle is only in direct sunlight while being ridden. The rest of the time it is parked in my garage or under a shelter at work. The turn signal mounts are also deteriorating. It will only be a matter of time before they fail and the signals are hanging by their wires.”

   NHTSA complaint #10235976, filed 2008-07, 2,500 miles
3. 3
   Suspension

   Rear shock preload adjuster fails

   • 9 complaints (8%)
   • median 1,504 mi at 0.2 yrs old (8 state mileage, few)
   • filed 2007–2008

   Owners report that the rear shock preload adjuster breaks or spins without changing anything when they try to set the shock stiffer for a passenger or heavier load. Several say they followed the owner's manual procedure and that the adjuster failed at low mileage. In some cases the dealer replaced the shock, while other complaints say the rider was left with the shock stuck on its softest setting. Reported from very low mileage up to roughly 5,000 miles, typically the first time the rider tries to increase preload.

   What to check: Turn the preload adjuster through its range and confirm it actually changes shock preload and does not spin freely. Ask whether the shock is original or has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I tried to adjust the spring preload to a stiffer setting on my rear shock and the adjuster mechanism failed and the shock remains on the softest setting, unable to be adjusted. I wanted for the first time to take a passenger for a ride and now the stiffer setting required is not obtainable. Riding the motorcycle with a passenger could be a hazard at the current softest setting. …”

   NHTSA complaint #10221989, filed 2008-03, 1,589 miles

   “While adjusting the preload adjuster on my rear shock on my 2008 KLR650 the preload adjust broke. All it does now is spin and won't adjust the shock at all. I only have 1500 miles on this bike.”

   NHTSA complaint #10221640, filed 2008-03, 1,508 miles
4. 4
   Engine cooling

   Starter idler gear shaft wear in engine cover

   Mentioned in 4 of 60 sampled complaints

   A few owners describe the bore for the starter idler gear shaft in the left engine cover being machined too deep, letting the shaft drift and a spacer washer work loose inside the engine. They say this was found while doing other work, and some installed a spacer themselves to keep the shaft in place. Complaints note older and newer versions of the cover have a ridge that prevents this. Described mostly between roughly 3,500 and 17,000 miles, often discovered during other engine work rather than during a ride.

   What to check: Ask whether the left engine cover has been inspected or modified, and whether any spacer or updated cover was fitted; listen for unusual starter or lower-end noises.

   2 excerpts from owner complaints in NHTSA records

   “Cover side hole that lower starter gear pin rides in is milled too deep and can result in severe engine damage. While installing a balancer tension spring upgrade (another issue with these motorcycles) I found I had this issue. I had to install a spacer to fix and prevent the other side from coming out of engine side hole and causing damage.”

   NHTSA complaint #10334646, filed 2010-06, 6,100 miles

   “The starter gear shaft can migrate out in the left side engine cover, leaving the gear unsupported on the inboard side and allowing a washer to migrate loose into the engine--potentially causing the transmission to lock up or the timing chain to skip teeth and cause the intake or exhaust valves to hit the piston top, bending valves and making the engine inoperable.”

   NHTSA complaint #10334599, filed 2010-06, 3,500 miles
5. 5
   Electrical system

   Engine shuts off, wiring and oil leak reports

   • 8 complaints (7%)
   • median 3,475 mi at 0.8 yrs old (8 state mileage, few)
   • filed 2008–2010

   A few owners report the engine and lights cutting out without warning at road speed, with one dealer finding chafed wires under the fuel tank that blew a fuse. Another describes the bike losing power and stalling at very low mileage, and one was told by the dealer that the engine needed replacement because of oil leaks. Complaints describe the circumstances differently and no single explanation dominates. Reported between roughly 400 and 5,400 miles, often during highway riding.

   What to check: Ask whether any wiring repairs or fuse issues have come up, check for chafing near the tank and harness, and look under the engine for oil seepage.

   2 excerpts from owner complaints in NHTSA records

   “While traveling on main highway at 2am enroute to work I lost engine and lights. No warning. Unable to see anything let alone other motorists being able to see me. Replaced main fuse & battery...not the problem. Taking bike to dealer today. Out of warranty by approximately one month. Only 1500 miles on bike. Dealer claims electrical shortage somewhere??? Could have been seriously injured or killed.”

   NHTSA complaint #10243852, filed 2008-09, 1,500 miles

   “I purchased an enduro motorcycle for use on the highway,the motorcycle is equipped with all necessary components for that purpose. The first problem was the speedometer was not calibrated to the fault that I never knew what the reading would be evan at the same estimated speed. I used the motorcycle on mostly surface streets. On the evening that the motorcycle failed it seemed to get a boost of power so to speak, then it started to rapidly loose all power until it would no longer continue run. …”

   NHTSA complaint #10233265, filed 2008-07, 400 miles

Buying note. On a used 2008 KLR650, look closely at every rubber part, especially the turn signal mounts and windshield well nuts, and test the rear shock adjuster before agreeing on a price. Ask for service records covering wiring repairs and any engine work, since the low-mileage complaints are the ones most likely to still be relevant.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.