2004 klr250
Posted: Sun Dec 07, 2003 4:40 pm
I picked up a new 2004 KLR250 for my wife a couple of months ago. The
bike seems to have some sort of alignment problem and I was wondering
if anyone else had heard of this. When I purchased the bike, I rode
it home from the dealer. For the first mile or so, it seemed to give
off some bluish-white smoke from the exhaust area. I had purchased a
KL125 for my son at the same time, and the dealer had agreed to
follow me home with the 125 in the back of his pickup. We both
noticed the smoke, but after about a mile it went away, and we didn't
think much more of it. We got the bikes home (about 4 miles from the
dealer), and the next day I was looking over the 250 and noticed that
the rear tire had been rubbing on the muffler. That was what made the
smoke. It appears the tire was just barely rubbing the muffler, and
it only took a mile or so to rub the corner off the first row of
knobs and create a little clearance between the tire and the muffler.
I called the dealer and explained the situation, and he said to bring
it on in and they'd take a look at it. I then began looking the bike
over really well and when you look straight on from the rear it
appears the rear wheel is tilted to the right (muffler) side at the
top by at least a good 1/2 inch or so. I wasn't sure the cause of the
tilt, and brought it back into the dealer. He kept it for a few days
and Kawasaki replaced the rear tire and the muffler (some paint had
rubbed off the muffler) under warranty. He also shimmed the rear
muffler mounting bolt by adding a few washers between the muffler and
the frame. He said he had contacted Kawasaki and they had checked a
250 at the warehouse and they could barely fit a piece of paper
between the tire and muffler when the rear suspension was compressed
as with a rider on. He said Kawasaki had instructed them to shim the
muffler. I thought this washer repair was kind of mickey mouse, but
took the bike as we had a ride scheduled that weekend.
During the weekend ride I spent some time following my wife with her
on the KLR250 and I on my KLR650, and it definitely appeared that the
back wheel of the 250 had a tilt to the right at the top. After a
couple of outings I decided to look into this a little further. I put
the 250 on my motorcycle lift and removed the front and rear axles
and slipped in a couple of 3 foot steel rods in their place so they
would stick out a foot or so on each side of the bike. If you view
the bike from the rear the two rods are not parallel. The rods
definitely show a tilt to the right at the top of the rear wheel. I
did not go further and replace the swingarm pivot bolt with a rod, so
don't know for sure if it's in the frame or the swingarm.
Anyway, I've brought it back to the dealer, who as of yesterday has
it out at a frame shop getting the alignment checked and trying to
find out where the problem is. During one conversation with the
dealer, they said that Kawasaki was aware of this problem and had
stopped shipment of 2004 KLR250's. I'm supposed to call the dealer
back on Monday and get an update. I've seen some of you have posted
about purchasing 2004 KLR250's. Anyone notice anything like this on
their bikes? When I was in the dealer a few weeks ago he had a used
KLR250 (Barbie style, not sure what year) that I looked over pretty
good for comparison and it didn't show any signs of the misalignment
I'm seeing on my 2004. I'd appreciate any info or insight any of you
may have.
David Muhlenkamp
2002 KLR650
2004 KLR250