Kawasaki Safety Issues and their little SECRET Exposed 

I just get mine and same problem...2023 KLR650. Dangerous. Thanks for take your time and upload the video, it was very helpful. I'm sure you save life with this. Thanks one more time.

I’ve had my 2023 Adventure for 2 months and like you, I thought it was a “me” issue. My bike exhibited the same exact symptoms whenever the front suspension would load. Had my dad take the bike for a quick ride and within 45 seconds he noticed an issue with the steering. I brought it in to the dealer I purchased the bike from and they disassembled everything to ensure the bearings and racers were not scored (read about it on a KLR forum post). Luckily, there were no hardware issues. They put it back together and re-torqued the steering nut and it’s as if the bike is completely different, in a good way.

I’d be filing a compliant with the NTSB. If it is a known issue from the factory they are liable. The reason they dont want to tell the dealers is they have to pay the dealers to fix the problem, labor costs. Glad you got it sorted.

Yep. 3,000 miles on my 2023. Got in April. Still fighting the steering. When I reached out to the dealer they gave me the run around. Even said I would probably have to pay for the repair if I want the bearings checked. Kissed me off so I just been riding it. Slow speeds suck. Now that I am armed with this information I am definitely getting it fixed.

Great info for KLR owners and since it's hot news at the moment; I wonder what your CTR would look like if you had *"DOES YOUR KLR SERIAL # BEGIN WITH ML?"* prominently on the thumbnail? Either way. Thanks for sharing, I'll lock away this little bit of knowledge and surprise my KLR friends with it! I'm your 500th subscriber as well!

Glad you put this out. I have a 2022 with no problems. I want everyone to enjoy this bike as much as I do.

I haven’t had any trouble with my 2023 KLR S. In fact, I was surprised how good it handles. I was expecting it to feel top heavy. Surprised it doesn’t, at least to me. But hey, everyone rides little different. I’m 75yrs old and have owned 28 motorcycles. Have ridden just about every type of riding a person can do, including track days on sport bikes. This 2023 is my third KLR. Besides this bike, I currently have a 2022 KLX300 and a 2023 GSX1300R, Hayabusa. I really like this KLR.

I agree totally ! I had that issue , called the dealer about the steering and they said they had no idea of this issue . Because it's a 2 hr drive I fixed it myself . Your video was spot on.

Hi from Australia. I bought my 23 in Febuary. It's an ML and had the steering problem. Dealer eventually backed off the top nut a little bit but they did not test ride it. Even told me that maybe the issue was not the bike.😅 Ended up pulling it apart myself and fixing it. The top bearing was not greased only a smear on the race. I don't think you can say you have fixed it properly if you are only backing off the nut it needs to be inspected. Once fixed it will put a smile on your face to ride it without the problem. We just want the bike to steer normally and that's not too much to ask. Dealer said as far as a warranty issue is concerned unless something breaks or the bike won't go then it is not a problem that would be covered. Shame on Kawasaki for not doing the right thing. It takes the shine off buying a new bike. You are good mates with the dealers when buying the bike but they are not so helpful when you bring it back.

NOPE....My Gen 1 still ain't fer sale.....Good luck with the Gen 3's ya'll....

Maybe that's why a dealer in witicha only offered me 3000 for my klr adv on a trade for a truimhp900. The klr have less than a 1000miles.

That’s just crazy brother. I can’t believe they kept that hidden from their dealers. Kind of an important detail. Kudos to your dealer.

Brand Noob here . Bought a KLR650 and it’s in the shop being looked at thanks to you . Also, I bought a Z650cc and right after the first service. 600 miles it broke down as I was leaving Destination Powersports in Punta Gorda Florida. Dealing with Adam and Zack in Service there . The stator went bad on the Z650cc. Really disappointed with Kawasaki. Zack jumped on my KLR650S and said something wrong with the steering as well. You saved my life. Kawasaki really seems to be declining in quality. 2 bikes 2 different models. Nothing but problems.

I wonder why the factory didn't call all the dealers and say to adjust these bearings. And you are right, is there is a crash, I think the lawsuit will be crazy higher than fixing the bikes. Glad you found it and that you are now happy with the KLR. Ride Safe

I just bought a used 2018 and I think first gear is a little too fast But 5th gear seems perfect for cruising down the highway so I don't want to mess with the chain sprocket

Kawasaki said there are no problems.......Sounds like BMW.

Great catch and great post. Sadly, many similar problems seem to be emerging in the Mid Level ADV segment - several '22 T7's were shipped with the lower front fork nuts loose. I think the demand is so high that QC is suffering.

Japanese Manufacturers build each countries allotments in one bunch… So once you see one problem you are likely to see it repeat… the problem is they see it as less than 3% lets say reports it, so no problem… we saw it at Suzuki cars all the time… problem would show up in Chicago but not Arizona… this issue would be more across the board but maybe just being identified and dealer memo just has not gone out yet as they verify which production runs are effected… Glad they at least admitted to it once questioned…. Bet the memo is soon released…

Very helpful. A terrible problem. Potentially understeer into the opposition.

I also have a serial number starting with "ML" and have had no problems. Adventure model

Thanks for the information brother. The klr650 is one of the bikes I'm interested in buying . I talked to my dealership about the steering issue and they didn't hear about it. Sounds like Kawasaki is a company that can't be trusted. Thank you so much for the great video. 👍

My serial number starts with ML and no steering issues. Maybe my dealer knew about this and addressed it before selling?

You need to have them replace the head bearing. It was probably crushed when over torqued.

So what is the correct torque?

Thanks for the disclaimer, I'll be asking my dealer about this before I leave the lot. The bike that I'm looking at does start with ML in the VIN number, is that what you're talking about?

We bought 2 23 KLRs. Mine was perfect, my dad's suffers from this issue. Disgusting that they're just letting this happen. I'm too scared to ride my dad's bike, it's straight up dangerous.

This may not be Kawasaki - Dealers set up the bikes when they get them - a lazy/hung over mofo tech will ruin your day - then make up a story. I got my brand new Honda $20K bike with the rear wheel out of alignment and the tires extremely low on air.

Thanks for the heads up. I've had my orange 22 ABS Traveler for a little over 2 months and haven't noticed any steering issues. (Id starts with ML) I'm actually pretty impressed with the handling and overall ride quality. I can turn quick slow speed uturns on narrow country roads no problem. I will however keep an eye on it. (Put 900 back country miles so far on it with weekend and occasional afterwork pleasure rides)

wow..kawa admitted it was a problem and didn't contact all dealers and owners...the liability on this issue is thru the roof

I wonder if 2024 models will have this issue. I really like the new color schemes and hope it's been resolved. Definitely bringing it up to our local dealership. Thanks for making this public.

I sold my '22. I didn't like it as much as my '12 or '14 If I can remember I didn't think it handled the same. Kawasaki sux.

Thank you bud, thinking this was my imagination. Multiple 2023 KLR 650 owners have posted this exact same problem. I’ll be bringing my bike to the dealership ASAP. Thanks again, stay up 👍🏾

I have a 2022, and I have a crapy OEM spring problem. Built for lightweight ppl

I have a 23 adventure with ml in number and have not had a problem, picked up may 3rd

I had them replace my bearings and races outright and repack the grease/retorque.

Oh my lord!! Thank you for making this video. I happened upon your video through sheer synchronicity and am so thankful. I am a lifetime street bike rider and this is my first ADV bike, so I thought it was just me. I kept adjusting the psi and was about to buy all new different tires because the steering has been such a problem. I am going to my dealership right away with this information. And yes my serial # starts with an ML. Thank you, thank you!!!! And SHAME on Kawasaki!! As a female rider who rides alone I do not appreciate their negligence!

Let me just ask if this has affected the KLR 650S.

the old klrs didnt have this problems ! ;-/

Hi, from Oz, I have the 2023 ML serial plate, mine is and Adventure model, 1500 km (932 Miles) with abs, no problems on or off road yet... is it model specific?

My 23 suffered from this. Picking it up from the dealer today. New bearings and races covered under warranty.

That is why I’m going to the Yamaha Tenere 700 🖕🏻Kawasaki and rods ride on Powersports of lacrosse Wisconsin ‼️‼️‼️‼️

Ok pump the breaks there Nancy! A steering stem torque too tight is not a dangerous safety issue. You will wear out the bearing a bit fast but that is it. Use those man mussels to power through a slow speeds. Should it be fixed; yes. Are you gonna die; well if ya do then ya shouldn't have been on any bike ever. Should Kawi address it at the dealer lever during your next service; sure. These things happen, it's an oversight at the factory, even though they are Japanese, they are still human. Wow how about some Grace!

I have a 2022 adventure model and haven't had any problems with it. In fact, I think the steering and handling at slow speeds is fantastic.

Just looked at my SN and it has the ML, I gotta wonder if the dealership loosened and retorqued the headstock nut?? the dealership I got mine from kind of sucks, they sent me home with the wrong paperwork first time, and then I got the right paperwork and inside the manual is a blank “presale inspection” sheet. My steering seems so smooth and has since I got it, no jerkyness, no wobble.. I wonder what the bearings and races look like in there, but not about to wrench on it until the warranty is up. But I don’t want the dealership doing it either. Kind of a bind (no pun intended) anyone know the correct torque specs?

Just checked mine & it starts with the ML. I’ve put 4100 on in 4 months & haven’t had any problems with the steering. I installed aftermarket pro taper Atv high bends handle bars on her right out the gate. Will have them look into it when I take it in to get a new ignition. Good info tho buddy

That explains why I’m seeing new Gen 3 KLR650’s selling in high numbers and for the prices of Gen 1 & 2 KLR’s. Sorry to hear of the problems with steering, I’ve heard of the fuel pump issues on them and now this.

I have replaced the bearings in a bike (not KLR) and just because I replaced every single bearing in my bike, and it does seem like it might be easy to over torque.

I got a 23 ml 600 miles in and no problems

Mine was so over tight that it damaged the races and bearings. The dealership had to replace everything.

And thank you much sir

They only put a smear of grease in there, and obviously overtorqued , just get the bike to the dealers, quality control out the window!!

Thank you! You may have saved a life or a dozen lives or more. Crazy that Kawasaki didn't contact 2023 KLR owners and dealers whose serial numbers started with "ml" IMMEDIATELY. Iron sharpens iron. Thanks again.

So far my bike is good, I think anyway. Turns good in my opinion. I will re torque it though.

Kawasaki should be sued!

There is MUCH more to this than just re-torquing the nut! The 2023- on KLR's SWITCHED from a tapered roller bearing to LOOSE BALL BEARINGS (1960's tech)! This IS NOT SAFE for this heavy and powerful a bike. No OTHER 500cc+ Dual Sport (dual purpose) bike on the market uses loose ball bearings in the steering head. We swapped-out loose ball bearings for tapered roller bearings on our 1961 CL350 Honda Scramblers-that's how long it's been KNOWN to be un-safe. Open the steering head and the 5/16"/7mm balls would have flattened spots on them, giving a "notchy" feeling to moving the handlebars and "loosey goosey" front end over hard bumps or dips.

Having to work to turn the bike is not good!!!!

I feel a lot of things are overtightened on these bikes. I have a very expensive torque wrench(480 bucks). When I went to change the rear tire after the factory wore out I had to use a cheater bar to break it loose. After putting it all together and torquing to specs I can now easily take my wrench and spin it off with one hand. When I changed out the front a month later I twisted the hex adapter I got from 3d. So I bought a steel large one and had to hook a large box wrench on it to get it loose. And since retorque to spec I can break it loose easily with one hand.

4:19 how does it feel now?

I've got a "ML" but only a 100 miles on it so far.. Haven't noticed anything yet. Does anyone know the correct torque setting? Thanks for the video :)

I just got a 2022 KLR 650 Adventure yesterday with very low miles 1238 miles and my SN# starts with M L do you happen to know what the torque specs are

I’m oz 2022 model non adventure model 1800km - I haven’t noticed any binding at slow speed - I’m an ML start of vin.

Sounds like a potential lawsuit there!!!

Hey mate. Just stumbled across your video. I just recently purchased the 2023 adventure. Was an ex demo model. My first ever road bike. Been mx/Enduro my whole life. I honestly didn't notice it and have done super twisty roads on and off road with the shit factory tires. (Work fine on road). Trying to wear them out so I can justify new tires. I'm always super focused on bike handling over the motor performance. Most bikes are fast enough for there intended use. I'm going round tomorrow night to redo my headset. I've done multiple dirtbikes before. At first I was like f%$#k off. You always know when your headset is too tight!... but maybe not on a heavier bike. And I'm going to the Burt Munroe challenge in Invercargill NZ on Friday. So.... should be fun. I might do the beach race for a laugh.

They DO CARE! THIS problem should have been caught in dealer setup. As for psi? You must own this variable. It is a tuning variable.....klr has rearward weight bias ans small cross section. 21psi I what manual says. Furthermore I have tech manuals from 7 tire companies..THEY ALL RECOMEND 21 PSI in front tire. I own klr650...I run 21 psi..works great!! Now that pressure compared to most bikes..appears low..or seems low compared to other bikes. But the 90/90 cross section is also much smaller than others. I suggest you defer to product planners and engineers who have worked hard to provide you with the best product possiable. It is regrettable this happened...would not happen in my dealership. All my people ride and are actively involved in the sport...they would catch it and correct it! There must be someone in that service dept that actually rides motorcycles. Find them and run questions past them. I guess some dealerships hire people to deal with bikes that do not actually ride bikes.

UPDATE : MY KLR HAD 1.9 FOOT POUNDS OF TORQUE TOO MUCH.

serial number? meaning the VIN ?

I had just bought a new 2023 klr650,last week 8/19/23 and after 133 miles and several close calls on my new bike,because of the stiff stearing,could not ride this bike off road at all.the shop retorted the head bearing nut and fixed ,how ever I could have been Injured or killed.if Kawasaki knew bout this they need to own up before they get there pants sued off them. 😡

Ya know, with nearly 40 years to fix the doo hickey, including 3 entire generational changes, and no fix *or even acknowledgement of the problem in the first place,* it's no wonder they wouldn't fix something like this either. 🙄 Kawasaki has always been this way, they give no shits about the consumer once the money has been handed over. Honda has a model right now that has a major front brake failure around 300 miles. The front brake starts vibrating terribly, almost to the point of losing traction. Dealer told me I was nuts. Forum says it's on every single bike. These Japanese brands are asleep at the wheel.

Shame on Kawasaki.....koodos to your dealer for stepping up!...great video...thanks for sharing....stay safe...ride safe!!!😎👍🤙👍🤙🇨🇦

Having fun on my HIMILAYAN 411

Great catch but preventative maintenance checks and regular maintenance checks and symptom troubleshooting would have caught that. Not saying Kawasaki is off the hook but too many people get into adventure riding thinking they can just get a cool bike, some nice gear and hit the trails. You need to learn a lot before getting into the mud, sand, water and mountains. Even the road. I love my KLR. Loved it before I bought it. Wanted it, researched it, learned about it and tweaked everything to suit my riding style. Every adventure rider is required to become a specialized mechanic of the bike they ride. Never leave your safety in the hands of anyone but you.

Good information. I kinda doubt that the dealer talked to the factory, probably Kawasaki USA headquarters. Language and time zone differences would be a barrier to talking to the factory.

This is why i do all the work on my bikes myself, 15 minutes with a castle nut wrench and you can adjust the steering head bearing to correct torque

what about the 2024? and how do you know? My steering feels fine, actually really smooth, but I am going from a cr250r so these heavy bikes are kind of new to me.

Not surprised at all Sir. When you said what the bike was doing the first thing that came to my mind was an over tight steam head nut. I’ve had this problem on other brands and know of others who have had the same problem. Glad they got you sorted out.

I have a question. After how many miles did this issue arise or was it straight away when you purchased it. My 2023 Is ML but seems fine (211) miles. Still new. Great State you are riding in as the scenery is awesome

Got same

You're right, Kawasaki doesn't care about some tight steering on a few $6500 motorcycles. sucks you got one of them. my 23 has been perfect. if it wasnt id fix it myself

I bought my KLR650 ML model number a few months ago and have had NO issues with the steering, I guess I’m just lucky:) however, this is my first adventure bike, and my other bike is a Harley Davidson fat boy with 18 inch ape hangers so staring at low speeds with it is pretty heavy, so maybe I just don’t know the difference

That is sad.

🤣 Promo`SM

Fantastic you have bike sorted Bob, but wow that’s very ordinary from the manufacturer thumbs down to them 👎🏻

My Kawasaki dealer basically told me it was my imagination when i mentioned the odd steering as described in this video. I found the fix on the KLR Forum and repaired it myself. i really like the KLR, but I'm kind of pissed off.

Can’t wait to see you out there doing jumps and tricks now!!

Thanks for taking the time to keep us informed. Let me ask you if if there’s an issue with the 2022 models. I’m considering buying a used 2022 KLR650. The serial # starts with ML… I’m kinda concerned. Thank you.

My 2023 had same issues with steering from factory My serial no. Starts with ML… the dealership fixed it at 1st service 600km I’m in Australia it was dangerous

Not all of them. Mine has been perfect from the mile 1.

Wow, and no recall on this model. Shame on Kawasaki. I'm so glad you have it fixed. Cheers Saddlebags ;-)

Thanks for doing this video mate. I’m now off to check my serial number….

I have a 2023 klx300sm I got on last friday and I’m having the same issue I’ve been to the dealer 3 times and even bought a new 120 front tire for more grip. But it’s only between 15-25 mph it’s an issue. My serial number starts with ML

They probably told the guy putting it together to make sure its tight for safety reasons but it's actually causing the opposite effect.

Good bike or not, I'd be real soured toward the machine and Kawasaki.... Glad you stayed on the problem until it was resolved and didn't get messed up from it.

Not a big issue. If it feels tight or too loose/floppy, Check the steering stem nut. Just like any dirt bike. Same for any motorcycle where it should be checked at first service.

I have a 22 basic model and the wife has a 24 basic model and luckily we never had any steering issues, my 22 had a starter issue and after having a new starter fitted is an A1 bike.

That’s shocking, Kawasaki should have come clean about this dangerous problem

That is some shady crap. Props to the dealership..

I just bought a KLX300 , in the back of my owners manual there is a page that states "If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration" it goes on to describe how , this page is in every new owners manual by law , please everyone do this !

cool facts to learn for sure! well done by you sir. sounds like the ole money thing got in the way eh. Kawasaki dropped ball on this one, rare for them but unacceptable glad all is good dude now get off the pavement and find that dirt 🎉

I am a former Harley tech. Recalls are issued usually if a large number of their product is affected and a high chance of injury, accident, or death is involved with said issue. Years ago now there was a fuel pump recall that Haley had it affected the large cruisers, the amount of bikes that sold with later known probable defected part was quite large nation wide. Therefor a recall was issued. Now there was a issue with the Trikes at time, kind of major issue but it didn't affect the whole line. Once we as a dealer became aware if it officially we called our customers that had purchased one form us (I think like 6 that year), and told them to come by on Saturday get a hot dog we want to check their bikes. This became a tech tip, meaning "this needs attention if the unit comes in our possession weather service or sales". It may take a while for it to be as common as the dang doohickey but in time it will be resolved. It takes people questioning and posting to make things happen. Good on you for putting some light on this. I would add something to the title about steering so when another owner goes to RU-vid to find a help or options it comes up for them. Oh and thank you for noting your not a mechanic or tech......I had more "I tried to install this part and" ......tickets then anything else..If you are the least bit unsure see your tech... its cheaper than having fix it afterwards. Good viedo, great information, Love the KLR committee, keep up the good work.

mine starts with MLi I bought it last September its a 2022 I think that all Gen 3 must be ML . I am having no steering issues so it should be I guess just limited to the newer models.