Gen3 KLR 650 Factory Recall & Design Flaws

After 2 years of adventuring on my KLR 650 I decided it's time to trade up for something else... But before I do, I wanted to go over 8 common Gen3 KLR 650 problems.
KLR 650 Review Video: • Why The Gen 3 KLR 650 ...
More on the Thermo-bob & Doo-Hicky: • Can You Even Ride a KL...
KLR 650 Mod Playlist: • 2022 KLR 650 Accessory...
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Stay Swanky My Friends!

[@ronb218]

Hello Ben! I’m Ron a certified old guy, between a genuine formally new and pre decreptatude rider. I’ve owned and ride every type of motorcycle you can imagine sense 1975 to present and I just purchased my first KLR a week ago 11-24-2023 and freaking love it! I’m gonna brown nose you a little bit and say that your KLR videos have helped me MORE THAN ANY OTHER VIDEOS on KZbin by FAR!! Okay I got that out of my system.. keep up the good work! “ Don’t let your Meat Loaf!! Ron

[@SwankyCatProductions]

Hi Ron! That's awesome! I'm glad to hear you're enjoying your KLR, and I'm really, really happy to hear that you've found my videos so helpful! A lot of great things have come from creating videos like these, but being able to help people get out on their bike so they can enjoy this big beautiful world, has to be one of the best! Thanks for sharing!!!

[@RVAMotorsports]

I bought my 2022 Adventure model brand new. No dohickey, no thermobob, right at 4,900 miles, around 1000 of which are interstate miles at 75 ish mph. Zero issues, doesn't burn oil (I run 10w40 synthetic). Didn't take it in for the fuel pump recall. Bought the extended warranty and I'll just ride the thing, it's a tool and does it's job.

[@SwankyCatProductions]

Glad to hear it! Ride on!

[@davesmith3561]

Purchased my '22 KLR in Jan of "22, and put the thermo-bob mod on it immediately. With the thermo-bob installed, the temperature remains within 10 degrees f in all riding conditions. It also allows the engine to reach operating temps in less than 4 minutes in winter, less than 2 in summer months. I have 3k miles on the bike at this time with zero oil burn, which I wouldn't expect at this point with or without the TB mod. But this engine is bulletproof and will run a long long time, with the proper maintenance. Doo-hickey mod coming this summer.

[@SwankyCatProductions]

Good way to do it. I'd probably do the same if I planned on putting on a lot of miles.

[@williamb.6918]

I had a 2015 without the Thermo. It would not burn a drop of oil if it was kept under 5500 RPM, but riding with an 1190 that was not a reality.

[@Kevinhobbytime]

I have no mods on an adventure model ‘22 and have not noticed any oil burning in 3500 miles. Im probably going to do the thermobob but not right now. I really have no plans for the doohickey.

[@HooDRidEWhiteY]

Im not going to do the doo either 👍🏻​@Kevinhobbytime

[@Werkmaster666]

I have about 5k miles on my 23 KLR with no Mods and no oil burn. I believe issues have to do with riding conditions and rider type example long highway riding, excessive RPM at low speeds, bypassing clutch switch to keep idle up. My issues are all bolts on the bike were overtorqued to the point had to have warranty work on the steering stem, frame bolts plastic panel, wheels, chain idle tensioner, etc. All within the first 10 miles of driving off dealer lot. Also people claim issue with stock tires still running stock at 5k plus miles and most can't get beyond 2500 miles. Riding conditions is about 1k miles off road and 4k on road.

[@squarewheel142]

I have had a 2015 KLR since new, have over 41,000 miles on it & it never seemed to have an oil consumption problem, I run 10W40 synthetic oil and have always added 1 OZ. Marvel Mystery oil to each 2.5 Gallons of fuel, which may not work so well on the Gen 3 bikes with Cat. converters on them, my 2015 still runs like new..Bike is 100% stock.

[@ericdustin4663]

First of all, thank you for all the information on the klr650. Your tutorials have guided me through all my upgrades from tire change, oil change, and other add-ons for the bike. you do a great job educating the non-machanical person like myself. again, thank you.

[@SwankyCatProductions]

I'm really glad to hear that, thank you!!!

[@trevorwhite7203]

My grandpa has a 2022 KLR and it has 200 miles on it. I’ve ridden it a few times and have never had a single issue but my grandpa did make the comment that when it’s cold it does seem to struggle to start and stay running.

[@towntourin]

Thanks man, I just sold my goldwing, At 60 yrs. young Im going to get a 2023 KLR. Love all your vids. Learned a lot and will do the mods myself. After working on goldwings everything seems easy to work on LOL. but these motors seem solid and easy to work on even for beginners. also the price. The bang for your buck either way I think you can't go wrong. Thank you for your vids man.

[@jameswatson5831]

I did the same thing sold my goldwing after 17yrs now I have a 22 klr 650 and enjoying it just as much it's the perfect bike for a 64yr old tired man that still loves to ride

[@mkramsauer]

Awesome freaking review brother 👊 everything I did was because of your videos. Super helpful and just rad content

[@robbieandbeckie]

My 2005 Gen1 is about 23K miles, and there is absolutely no oil consumption. No thermobob. I pulled the stator and cover and checked the counter balancer chain. I adjusted minimal slack, and factory doohickey spring still had tension after adjustment. I put the Eagle Mike kit back in the toolbox. It is smoother running after taking the slack out of the counter balancer chain. A good mod for the KLR is the Procycle polyeurathane cush drive kit.

[@rhllnm]

Ditto for my 2007 (bought new) though my doohickey was broken when I checked at roughly 5,000 miles.

[@robertgullickson8758]

Thanks for the information about the headlight adjustment. I’ve had trouble with that. Otherwise, in 2,000 miles I’ve had no trouble. Loving this bike.

[@shortattentionspangarage1312]

Thanks for the recap. I just got a 23 KLR650S and have noticed a few of these same quirks.

[@Daron1133]

Mine has none . Its badass

[@todd5052]

Awesome video! Thanks

[@SwankyCatProductions]

Thank you!

[@chuckb.5076]

Great video! Super informative. Thanks

[@SwankyCatProductions]

Thank you! Glad to hear that!!!

[@mikebetts9677]

Hey Ben. Thanks for all your KLR videos, I've enjoyed them all and learned a lot from them. I had to lower my lights just as you said (btw, they are excellent, aren't they), and I experienced the fuel pump failure at 200 miles on my '22 KLR. It simply cranked and cranked but wouldn't crank over and fire up. After 2 months in the shop they finally got a replacement fuel pump and fixed it. Shortly after that, Kawasawki announced a recall. I wasn't surprised, having already surmised the lack of replacement pump was due to many fuel pumps failing. My magnificent KLR has been wonderful in all other respects and I love it! Happy riding.

[@kwils6685]

I also had to adjust the headlight down on my 2022 KLR. Like you I too think the light is very good, but I do have one issue, and that is the blue high beam indicator is just far too bright for my liking! I haven't really heard others complain about it, so maybe it's just me, but I've been caught in a little rain a few times, and after my helmets shield is covered in water droplets, turning on the high beam then rewards me with what looks like an entire star field of blue dots right in front of my face! I'm curious if you or anyone else is bothered by that light, or maybe I'm just really sensitive to blue light. Happy riding as well!

[@hellraisingvtec]

Great video man. Thanks

[@SwankyCatProductions]

Thank you!!!

[@Schlabbeflicker]

Wish Kawi didn't drag their feet with the fuel pump recall. Had my KLR fuel pump conk out in the desert... in summer.... 300 miles from home. When I called the dealership, they knew immediately what the deal was and said they were just waiting for Kawi to issue the recall order. They suggested I wait for the temperatures to drop and the fuel pump might work... again, in the desert, in summer. Ended up spending $300 for a tow home, but the fuel pump was replaced under warranty. Still really stupid for a bike whose primary selling point is 30-year-old simplicity.

[@SwankyCatProductions]

Wow that really sucks, I can see why some people got so frustrated with Gen3s. I never really though about it all that much, but I wonder why they couldn't just reuse a fuel pump from one of the hundreds of other bikes and equipment they sell. Seems odd to start from scratch if your putting it on old reliable.

[@MrPepper312]

The fairing squeek on my Gen 3 was fixed with a peice of rubber were you can't see it.

[@Korrupted8787]

I have a '22 and had the recall for the fuel pump, I chanced it and wanted to wait for the winter season to have it fixed. It failed this past September at around 8,000kms. When I would turn the key on their would be a low rattle/clicking sound rather than that hum and the bike would just turn over but never fire up. The last few days before it failed the bike was hard to start during cold start's. Like it would take 5-8 cranks to fire up.

[@tippytailmckitty2658]

Good video. It can be hard to pin down starting issues.

[@Texan_American]

Dang only 3300 Miles? I'm about to hit 20k.

[@simob7862]

I had the Last generation KLR and I had a Lot of trouble with it drinking oil on trips over a few weeks and running at 100km on the highway. We replaced the thermostat and the dohickey as well as the clutch plates and the a bunch of other things. It was an okay bike but it did leave me stranded on the road a few times with breaks downs

[@richschuster1097]

Awesome video once again. Ben or anyone else who knows; do mods for the gen II work on the gen III (foot pegs, crash bars, windscreens, luggage racks)? My gen II has a bunch of mods; if I get a gen III, am I starting over?

[@deltabravo1257]

Nice studio set up in the side area of your shop / garage. A few other moto KZbinrs I watch do their videos in a massive cluttered corner in their garage and it's so distracting looking at the mess. Your wireless mic is a nice touch too. I'm curious what you will replace the KLR with.

[@SwankyCatProductions]

Thanks! I'm glad to hear you appreciate it. I've been doing a lot of these types of videos recently where I use clips from old videos, a lot of them are from before I painted the garage and when I just used the camera mic. Oh man does it drive me NUTS to watch and listen to them now! 😂 What was I thinking!!! Haha. Live and learn though!

[@colinlawrence6403]

I definitely had to adjust my lights, luckily the adventure model driving lights you don't really see the low beam anyway. I also loosened my stem nut, not that it was really tight but it wasn't free moving either, had 3400 miles when I did it. Personally the biggest mod you should do is put the magnetic drain plug in it!

[@bluezhawg2104]

Can you explain how you determined the magnetic drain plug is the best mod?

[@colinlawrence6403]

@@bluezhawg2104 because it collected and metal particles in oil from gears.

[@bluezhawg2104]

@@colinlawrence6403 You had metal on it?

[@colinlawrence6403]

@bluezhawg2104 all motorcycle and atvs have metal in the oil, your gear case is included in your crank case.

[@gabrielkopp2036]

Well I owned a 2018 gen2 and my son owns a 2015 gen2 I did the doohickey and thermobob on both bikes..my sons bike had just over 6k on it and the spring was done and had been slapping the case my bike ha 3k on and the spring was done meaning no tension left.. the ge3 has the exact same motor the only difference is fi so yes it has the same issues they all did.. but I will say my sons bike now has 12k on it and don't burn any oil..as for mine idk as I sold it

[@PhillyN]

My 22 still does not like cold starts or if the bike is damp. Had the fuel pump recall completed.

[@chrismcgarity5868]

Hey Ben, probably too late but don't get rid of th gen3 you and I both have the pearl lava! Any way good video as always. I did go to my dealer to have the "recall" done...might have been a waste. I had 0 issues before and about 2300-2400 miles now right after it takes about 2-3 full cranks to fire off! Plus I found damage to the paint on my tank in that area and lost several of the side cover bolts after getting it back. You can't really prove it was there fault but I have feelings. Anyway I really like my Gen3 and I think I'll keep it. PS in South central PA if anybody cares. 😁

[@SwankyCatProductions]

Oh no! That really stinks! I think I noticed a few "witness marks" on my T7 after a recall. I suppose they're always being rushed, but it sure would be nice if they cared a little more... The Gen3 is with it's new owner already, your correct. It's a beautiful bike, but I actually traded it for the guys DR650 that I'm now testing and building along side my other new bike, an XR 650L!

[@dredude55]

I have a KLR 650 J Gen 3 2022 with 12 K miles. First owner did have to replace the fuel pump, it was a warranty covered/recall issue. In hot atmospheric temps, he was told, seals would leak. I have had no problems with it since I bought it 4 months ago.

[@SwankyCatProductions]

Glad to hear it! Thanks for the fuel pump report!

[@marshallsac646]

The speedometer on my 2023 quit working as well as the horn. Also my steering is chopy and the headlamp was pointed up as much as it could go.

[@genxlibertarian9656]

By contrast, the headlight on my 23 z650rs was pointed nearly at my front tire.

[@JoeImburgia]

I actually had a weird electrical issue, which I haven’t seen anyone else have yet. Essentially, a bolt under the tank chafed the ignition wires causing the bike to randomly shut off while out on a ride two times. The one time I was within the neighborhood. The other was about a 2 mile push… I plan on making a video at some point about my issue.

[@SwankyCatProductions]

Ouch, that's definitely a good one to keep an eye out for and to know about!

[@CasualMoto]

Bought my '23, rode it home, put the Thermobob mod on it. Why? Just because the Thermobob makes sense. If you spend a few minutes thinking about it, high oil consumption on an engine that has uneven heat distribution should be obvious. With the Thermobob on the KLR, the engine temp comes up quickly and evenly, and stays pegged in the 180-200f range, no matter the type of riding. The Doohickey is critical, but the Thermobob should be first.

[@Daron1133]

The shifter. I wear motocross boots. we all know the shifter is to small. I put mine one notch up. but then it hits the case. i just grinded a bit of the part that hits and painted it. Also the lower footpegs. Perfect

[@stevec3936]

My 23 has issues starting when it's hot outside and just fine in colder weather. She just needs 2 cranks mostly to get going over 90 degrees. I'm in Vegas so it's almost always hot out. haha

[@SwankyCatProductions]

Mmm yeah I suppose I've never even started mine when it was 90 degrees out. We just hide in the AC when it's that "hot" haha.

[@Daron1133]

Tusk battery. MOre power less weight

[@danielghanayem3909]

I had a no start below freezing. Dealer replaced the exhaust cam.

[@SwankyCatProductions]

Did I read about that on Facebook? Where the exhaust valves open slightly during the compression stroke or something?

[@andrewmangum8391]

Did we finally do a recall and fix the damn doohickey

[@SwankyCatProductions]

Haha. No, you'll never see one for it. The vast majority of issues people see are well out of the warranty window. So unfortunately at that point, they can't really be held liable for it.

[@etienneyomegnedjeugotassa614]

When to do the first oil change please??

[@SwankyCatProductions]

I did my first at 600 miles. Then again at 2000.

[@crazycooter1510]

The notchy steering is not specific to the KLR650, my KLX300 needed new steering head bearings from the factory they tightened it enough to cause flat spots.

[@AUBREYTHOMAS1979]

The cold weather starting issue is not just a KLR problem but a big single cylinder bike problem in general, particularly on some of the higher compression ratio bikes. From most of the digging into that problem I have done it come down to the battery not being able to supply enough cranking amps to swing the motor fast enough to get it to fire up. There is a few nice lithium batteries available that have better cold weather survivability and more cranking amps to boot. Chat to a proper battery expert in your area to see what they can get for you.

[@fishinkarts2865]

My '87 starts just fine in sub 20 degree weather with a battery that can just barely get it cranking after sitting for a few months.

[@SwankyCatProductions]

Very solid point. My dad's Super Sherpa has a similar issue actually. I think people were having trouble getting it to actually fire though. Not so much that it wouldn't turn over. I could be wrong though?

[@Daron1133]

Tusk battery.

[@danielw.9090]

You Rock. enuff said, thanks bro

[@jaimea2722]

Love my Gen 2. No FI nor computers or any potentially un repairable parts

[@bravohomie]

3 months, 4.5k miles and the exhaust valves were tighter than a nun

[@paulyg3776]

My new gen 3 did have an issue starting. I think it happened after the recall due to a dodgy mechanic

[@SwankyCatProductions]

Oh no!

[@jmabbott888]

Something to think about with the "required mods"..... KLR has been around since 87.... how many are out there? My best guess from info available would be 150k to 200k.... how many recalls on this bike for the "must do or die" problems? There is a reason recalls are issued and a reason the manufacturers are mandated to have them. Why no recall for these issues in 35+ years.

[@lesterroberts4787]

In regards to the DooHicky, there have not been enough catastrophic failures to warrant Kawi to make a recall and that is do to when a doohicky might fail, usually in the higher mileage bikes. If you look on line or follow the KLR forums you will see things like, Just found an '04 with 1100 miles on it, I just seen a guy buy an '18 with just over 300 miles on it. Where I'm going is , most people don't ride them far enough to see a failure and those that have seen failures will take precautions and end up with very high mileage bikes. I run a '22 Traveler with ABS, was on the fuel pump recall [ my dealer did it the same day I took it in] I have done the Thermal Bob and will do the Doo and low profile drain plug at my next oil change along with a valve adjustment . My bike runs great, doesn't burn oil and fits my butt perfect. My other mods are JNS lowering kit with better pegs, Aluminum skid plate, hard wired Garmin ZumoXT2, windshield risers [I'm 6'-2" 200lbs], Tusk Olympus bags, Tusk Tank bag, Tusk crash bars just like Bens , Handle bar risers and the next mod is some driving lights.

[@jmabbott888]

The fuel pump recall makes my point..... if it's a problem the manufacturers are required to have a recall, just ain't seen enough for the dohicky over 3 generations and 35+ years but the hype of "do it or blow your bike up" is there for sure.

[@kyleklintok7730]

I have a dumb question. If the original doohickey springs break, why can't you just buy the stronger springs? Why do you have to replace the actual doohickey?

[@SwankyCatProductions]

You 100% could do that. I think most people don't, just because they figure they might as well do the whole thing while they're in there.

[@Daron1133]

Some never do it and never have a problem. Just ride it.

[@krashgamingandoutdoors1125]

Anybody seeing any white substance in your coolant reservoir? Mine had it from the dealership.

[@SwankyCatProductions]

I think I did actually see something in mine at one point but then it was gone after while. Not sure what it would've been.

[@krashgamingandoutdoors1125]

@SwankyCatProductions I just flushed my system and if I see anything else I'll worry about it. Thanks for that part about the headlights. I had no idea it was that simple and mine was pointing way up because it has a lowered link on it. If my coolant system craps out for any reason I'll post back here and let you know. Keep it swanky bruv!

[@martychin9496]

I have owned all three generations, only lost the lower subframe bolt on a Gen2 in Mexico, it's an oddball shorter-length bolt than the right side, other than that my GEN 3 2022 was a total piece of shit, mainly due to assembly issues, they just didn't care, got it fixed and sold it in two months. I changed all of the dohickeys except the Gen3, none of them needed it, and none had any damage or spring damage. I wonder Eaglle Mike told me over the phone Kawasaki fixed the doohicky in 2006, but the demand is still there so he keeps selling them. I think most of the doohicky or the springs fail due to improper adjustment and or failure to lock the bolt down properly. Thermo Bob, never needed or used one, never had any heat-related issues, give it time to warm up, never an issue high or low speed, metro or desert. All single-cylinder scooters or motorcycles will have oil consumption at the higher end of the rev range, the 08 had an egged-shaped cylinder in some of them, my 08 did not burn oil, but I didn't ring it neck as many did. Break it in properly, use good oil, change it on time and don't abuse it, and it really did not have oil consumption, at least mine didn't. I did have an over-torqued head-set by the factory, KLX also had this intermittent issue, probably a problem with the assembly tool maintaining proper torque at the factory. So far my Gen3 2023 Orange, other than over-torqued head set has no issues.

[@GoldGunsandGolf]

So I have a 2022 KLR, it has 14 miles on it... not kidding, bought and put in storage. I'd like to get crash bars on it, but every set of crash bars I see have the factory flood lights removed and changed. I cannot for the life of me figure out what bars I can get and still use factory lights, I don't want to waste perfectly good lights.... HELP!! PLEASE!!!!

[@Daron1133]

I have adventure. 2023. Dirttrack crash bars. They are heavy duty tank material. Amazon. Get that thing out of storage and on the trail

[@iCraftSouls]

23 klr 650 only had the squeaky panel

[@SwankyCatProductions]

Haha 😂 glad to hear that!

[@gcprost]

I put a down payment on a 2023 S version of this bike and I must say I’ve become a little nervous about all the issues with this bike.

[@Daron1133]

No Way. Its a Fantastic Bike. i have ridden dirt bikes and harleys. this bike is so fun. yes a few up grades....exhaust , crash bars, skid plate.... but solid bike. Get the Leo Vince exhaust...badass. I have the 2023 adventure. They are the most reliable bike out there. they are tanks. Thermabob also. easy to do. hella easy. best wishes

[@maytronix7201]

My biggest issue with my 22 is fork dive... there are fixes out there but you can really eat shit on this bike if unaware.

[@SwankyCatProductions]

When you're braking? Or off-road?

[@Daron1133]

Progressive springs. add a tiny it of oil. Cheapest and easiest upgrade to do. huge difference. fork brace also. Big difference

[@jayhopkins1337]

None of this is surprising to me. KLRs have been letting people down sence they came out. Im glad this day and age people can go online and see these bikes are built as quickly and cheaply as possible, and wont last unless you baby the hell out of them. I've had 2 friends that had them and both have sold them within 2yrs. I rode them as well. And was very unimpressed

[@Daron1133]

I love mine. been Riding all my life. Dirtbikes, Harleys. For What it is its a tank. Heavy ! If you can buy something fancy do it. Reliable. leovince exhaust, loud insert. I love mine

[@georgewright9415]

Needs 6th gear

[@1sinister80]

I just got a new 2023 adv model. I will not do any mods. I have a 4 year warranty so not concerned. Kawasaki built these to run the way they do for a reason.

[@mattsloop2736]

Its sad they say you gotta do so many mods to a bike to make it reliable. All that and its still under powered. No reason for that.

[@jackblock777]

I would never buy one with so many other amazing options out there.

[@shreksexy6879]

Or just buy a Tenere 700.

[@SwankyCatProductions]

I use to think the Tenere 700 was the next logical step after a KLR. But honestly I think the vast majority of KLR owners might actually not like the T7. The ones looking to ride harder and faster, well of course they'll want one. But those who are more interested in just thumping along will probably find it too aggressive and kind of harsh. They both can do the same job, but they go about it in totally different ways.

[@shreksexy6879]

@@SwankyCatProductions KLR 1000 would be a very interesting upgrade.

[@alank808]

thermostat regulates cooling fluid flow in cooling system. Point blank not rocker science. Always someone trying to re invent the mouse trap.

[@darrenvanmeter1411]

You are full of crap. I owned gen 1, 2, And 3. None of them burned oil.

[@SwankyCatProductions]

3 out of 3!?!? No way!

[@obamavariant9128]

It was mostly the 08