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Vehicle recall 09V059000 · February 19, 2009

2008-2009 Kawasaki KL650E

The muffler assembly is secured to the frame of the motorcycle by two bolts.

Source: NHTSA data as of September 22, 2026. Last refreshed Sep 23, 2026, 2:43 AM UTC.

Summary
Kawasaki is recalling 16,167 my 2008-2009 klr 650 (KL650E8F/l, KL650E9F/l) motorcycles. The muffler assembly is secured to the frame of the motorcycle by two bolts. It is possible that heat expansion cycles of the muffler, combined with vibration from vehicle operation may cause loosening of the muffler mounting bolts.
Consequence
If the bolts loosen completely, it is possible for the muffler to separate from the motorcycle, creating a risk of a crash resulting in injury or death.
Remedy
Dealers will remove the paint from the muffler mount tabs and replace the mount bolts, nut, and washer free of charge. The recall began on February 23, 2009. Owners 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://www.safercar.gov.

Recall details

NHTSA campaign
09V059000
Reported to NHTSA
February 19, 2009
Filed by
KAWASAKI MOTORS CORP., U.S.A.
Owner notification
February 23, 2009
Vehicles potentially affected
16,167
Initiated by
the manufacturer
Components
Engine and engine cooling › Exhaust system › Manifold/header/muffler/tail pipe
Recall 09V059000 on nhtsa.gov, with the manufacturer’s documents

Vehicles covered

As listed by NHTSA. A recall usually covers only some vehicles of each model and year, often a production date range.

Has your Kawasaki been repaired?

Recalls here come from NHTSA’s records for the model and year. Not every vehicle of a model is included in every recall, and this site can’t see whether a repair has been done. Only a VIN lookup can tell you that.

NHTSA’s VIN search doesn’t show recalls that were already repaired, recalls more than 15 years old, or some small manufacturers’ recalls. A Kawasaki dealer can also check your VIN. Recall repairs are free.