2009 Kawasaki KLR650 Problems: 2 Known Issues
2009 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated October 2026
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Preview the XT6 exampleAccording to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2009 Kawasaki KLR650 has 2 documented known issues, with 2 rated critical. The most serious are Main wiring harness chafes against the frame and cuts engine power - NHTSA recall 09V062 ($0-$0 repair) and Second recall for loosening muffler mount bolts - NHTSA recall 09V059 ($0-$0 repair).
All 2 Known Issues
NHTSA Recalls1 recall
STRUCTURE:MOTORCYCLE:KICKSTAND/CENTER STAND
ON CERTAIN MOTORCYCLES, THE SPRING RETAINING PIN ON THE FRAME MAY NOT HAVE BEEN COMPLETELY WELDED IN PLACE AND COULD FALL OUT, ALLOWING THE SIDESTAND TO DROP INTO THE "PARKING" POSITION.
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Frequently Asked Questions
What are the most common Kawasaki KLR650 problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2009 Kawasaki KLR650 has 2 documented issues. The most frequently reported are: Main wiring harness chafes against the frame and cuts engine power - NHTSA recall 09V062, Second recall for loosening muffler mount bolts - NHTSA recall 09V059. Of these, 2 are rated critical and should be addressed promptly.
Is the Kawasaki KLR650 reliable?
The 2009 Kawasaki KLR650 has 2 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: Main wiring harness chafes against the frame and cuts engine power - NHTSA recall 09V062 and Second recall for loosening muffler mount bolts - NHTSA recall 09V059. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Kawasaki KLR650 problems?
Repair costs for known Kawasaki KLR650 issues range from $0 to $0, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Main wiring harness chafes against the frame and cuts engine power - NHTSA recall 09V062, typically costs $0-$0 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2008-2009 Kawasaki KLR650 Main wiring harness chafes against the frame and cuts engine power - NHTSA recall 09V062?
Kawasaki recall 09V062/MC09-04 covers certain 2008–2009 KL650E8F/L and E9F/L motorcycles. The April 2009 supplemental filing lists 16,167 potentially affected units, built 14 February 2007 through 23 January 2009. Harness contact with the frame can damage wiring and stop the engi… Repairs typically run $0-$0. Severity: high.
What is the 2008-2009 Kawasaki KLR650 Second recall for loosening muffler mount bolts - NHTSA recall 09V059?
Recall 09V059/MC09-03 covers certain 2008–2009 KL650E8F/L and E9F/L motorcycles and replaces MC07-05 for eligible E8F/L models. Exhaust heat expansion and vibration can loosen the muffler mounting bolts; complete loosening can allow the muffler to detach and cause a crash. The se… Repairs typically run $0-$0. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public motorcycle data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.