Wiring Harness and Exhaust Recall- 2008 - 2009 KLR650

[Nibis]

Vehicle Make / Model: Model Year(s):
KAWASAKI / KL650E 2008-2009

Manufacturer: KAWASAKI MOTORS CORP., U.S.A. Mfr's Report Date: FEB 19, 2009

NHTSA CAMPAIGN ID Number: 09V062000 N/A

NHTSA Action Number: N/A

Component: ELECTRICAL SYSTEM:WIRING

Potential Number of Units Affected:

Summary:
KAWASAKI IS RECALLING MY 2008-2009 KLR 650 (KL650E8F/L, KL650E9F/L) MOTORCYCLES. WIRES IN THE WIRING HARNESS MIGHT BE DAMAGED DUE TO RUBBING CONTACT WITH A PORTION OF THE MOTORCYCLE FRAME.

Consequence:
THIS COULD RESULT IN LOSS OF ELECTRICAL POWER TO THE ENGINE CREATING A RISK OF A CRASH RESULTING IN INJURY OR DEATH.

Remedy:
DEALERS WILL INSPECT AND IF NECESSARY REPLACE THE MAIN WIRING HARNESS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 24, 2009. OWNER MAY CONTACT KAWASAKI AT 866-802-9381.

Notes:
CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO http://HTTP://WWW.SAFERCAR.GOV

[big_lv]

I wonder if I'll get a recall notice for this even though mine already burned and was replaced to the original spec location....

[Nibis]

That would be ironic.

[Hondo]

Stickied.

[Pstan]

I got my main harness recall notice today.  It also includes a recall for muffler mount bolts.

[enduroboy]

Just got a recall letter from Kawasaki that the muffler mount bolts can become loose to heat expansion of the exhaust pipe and vibration, also the main harness can chafe against the frame and cause the engine to stop, continued use could result in a crash resulting in injury or death. Kawasaki says DO NOT RIDE MOTORCYCLE UNTIL REPAIR HAS BEEN COMPLETED. Kawasaki can be reached at 866-802-9381 between 8:30 am and 4:45 pm PT Monday thru Friday.

[Hondo]

Thanks  -gonna merge this with the other recall topic.

[musclefixer]

So all the stuff I already put on the bike will be affected, no?
I mean if they have to remove and replace the harness.
Horn, relays, grip heaters, voltage meters, brake light modulator, heated vest harnes... Aye aye aye. 

[enduroboy]

Below is a copy of a recall letter I got from Kawasaki today:   



   Kawasaki Recalls 2008-2009 KLR 650 Motorcycles
February 25, 2009
Vehicle Make / Model:       Model Year(s): 
     KAWASAKI / KL650E       2008-2009
Manufacturer: KAWASAKI MOTORS CORP., U.S.A. Mfr’s Report Date: FEB 19, 2009
NHTSA CAMPAIGN ID Number: 09V062000  N/A NHTSA Action Number: N/A 
 
Component: ELECTRICAL SYSTEM:WIRING
Potential Number of Units Affected: 
Summary: KAWASAKI IS RECALLING 2008-2009 KLR 650 (KL650E8F/L, KL650E9F/L) MOTORCYCLES. WIRES IN THE WIRING HARNESS MIGHT BE DAMAGED DUE TO RUBBING CONTACT WITH A PORTION OF THE MOTORCYCLE FRAME. 
Consequence: THIS COULD RESULT IN LOSS OF ELECTRICAL POWER TO THE ENGINE CREATING A RISK OF A CRASH RESULTING IN INJURY OR DEATH.
Remedy: DEALERS WILL INSPECT AND IF NECESSARY REPLACE THE MAIN WIRING HARNESS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 24, 2009. OWNER MAY CONTACT KAWASAKI AT 866-802-9381.
Notes: CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION’S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153).
 

[Hondo]

Merged with a like topic -

[cbshaffer]

Well, I got my official wiring harness recall notice today from the Kawasaki mother-ship. Looks like a trip to the local dealer is in order for next week. I guess I'll have them do and oil change while it's there. I did the first one at the 200 mile point - the bike now has 400 miles. I already had to re-route my clutch cable - it looked like the dealer missed the cable loops on the frame, which caused the cable to rub (and squeak) every time I turned the handle bars. Other than that - so-far, so-good.

[brown]

You're not going to believe the crap.  Went by my dealer yesterday and talked to the assistant service manager.  He claims he doesn't know anything about the recall.

I guess I'll have to wait until I get my notice and take it up there and shove it up his........................

[lee1272]

The first time recall for muffler bolts must not have been enough to "get it right" !! After 6000 miles on my 2008 I would like to say I'm getting a little spooked every time I mount up ! I gotta believe Kawasaki should be ashamed of such basic design and inspection problems ! I hate to see their reputation of building a "bullet proof" bike suffer for the fact they can't route wiring and secure a damn muffler!! The dealer does not seem to care, as all the recalls puts change in his pockets. Also some bikes will leave the dealership in worst shape than when they got there ! Keep riding and always maintain your bike--trust yourself, it's your butt !!  Have Fun !! Lee1272

[JV]

  lee1272!

[Nibis]

Got, my recall for the wiring/exhaust bolts, and still need to take her in for the turn signals

[CWAY]

My local dealer here in MI claims that the wireing harness has been backordered for the last several months. But it is their fault my harness is bad not not Kaws the dealer cut the plug off the rear brake light switch pulled and pulled the wires together then installed a 40amp fuse instead of a 20amp and now my harness is melted and the dealer says they can not get a harness so we will see. I have not got my notice yet but when I do it is going to another dealer.

[Nibis]

Bummer, looks like they need to pull a harness off an 09

[SPANKY]

  lee1272!   My two dealership experiences have been terrible. Slow, I don't care service, from the Muskogee, OK. guys and bad wrenching (chain lube overspray on the disc, chain too tight, and an incorrect/pompous assed oil burning diagnoses) by the south Fayetteville, AR. weekend crew. I had an electrical issue. Worn insulation and wrap. I took the harness loose and ran the whole thing with "33" tape. I will respect the notice...but they damned well better not touch anything without letting me know.    

[Pstan]

  lee.

The last time I took my bike into the dealership for service (oil change and 4,000 mile service) they broke the left rear turn signal housing.  It still worked, but they had to order another.  Two weeks later another trip to dealer and 1.5 hour wait to just change the turn signal housing.  My recall letter said the wiring harness/muffler would only take an hour.

This I've got to see. 

[SPANKY]

Yeah ...me too!  Here it would be one hour and a month! 

[stainmstr]

I got my notice today. Been riding it for a year with no problems. But will see what the dealer says.

[tuckerman]

Dropped mine off yesterday.  Said he'll order the parts and call me in a week.  We shall see.

[SPANKY]

  tuck...hope it goes well for you!   

[oldstove]

Boy, reading all this I'm glad I stuck with my '03. Had actually thought of moving on to the NG but now I'm glad I didn't. And as an aside...anytime you can do your own maintenance the better. With surprisingly few tools, a good  maintenance manual, this forum for advice, and a little time, you get the peace of mind that its done right. Plus you prepare yourself for the inevitable and untimely roadside maintenance procedure. My bike, my butt, my maintenance.

[SPANKY]

Amen Stove!