2008 Redesign
In 2008 the KLR650 was radically redesigned with new aesthetics, modern dual headlights and a more powerful engine. The new 651 cc single-cylinder engine puts out 37 bhp (28 kW) at 6200 rpm and 33.4 ft·lbf (45.3 N·m) of torque at 4950 rpm. other improvements include: New fairing design, new instrument panel, redesigned handlebar control switches, new bar-end weights, revised powerband, revised suspension has reduced travel but with less static sag, new rear swingarm, new turn signals, larger petal-style vented brake rotors, new twin-piston rear brake caliper, increased radiator capacity, fork diameter increased from 38 to 41 mm (1.5 to 1.6 in), new headlight similar to that used on the Kawasaki Ninja 650R, larger luggage rack, firmer seat, larger-diameter wheel spokes. Stator "alternator" upgraded to 17amp output, providing an additional 36 watt capacity.
Criticism of the new design include its wide use of "sportbike plastics" for the new body panels which are prone to cracking and damage in the event of a tip-over, especially true for this genre of dual-sport motorcycles. First and second year models have been recalled due to the wiring harness rubbing on sharp frame edges which have caused electrical shorts and documented fires.
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