Doo Hickey Replacement, What All Do I Need To Order??? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 10 Old 08-05-2011, 05:48 PM Thread Starter
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Doo Hickey Replacement, What All Do I Need To Order???

What all is needed to do this job?

1- I think 2 special tools, an off set wrench and some type puller?

2- One or two cover gaskets, I see an inner and outer cover, is there a gasket for both? Is gray permatex sufficent for a gasket?

3- Parts, the "Doohickey" which I assume is the sprocket with lever, a grooved triangular part, a special bolt that tightens the triangular part, a coil spring to tention the triangular part and I also saw a different type of spring called a torsion spring the is circular in design, not sure about that piece???

4- Anyone give a good parts list so I'll have everything I need on hand to do this job. Thanks

P.S. If anyone has the specialty tools for sale, to rent or loan I would be interested and thankful. I'm near Raleigh NC.
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post #2 of 10 Old 08-05-2011, 09:44 PM
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Here's a convenient one-stop shopping place, but there are many on the net.

I would recommend that you get the basic kit, which will be the balancer lever and two springs. Add the torsion spring, as it is proving quite reliable and seems intuitively more reliable than the extension springs. It is officially recommended that the rotor bolt be replaced, as it is supposed to be a one-time-use. Do as you wish in that regard.

Your maximum outlay will be about $100 if you include the gaskets. Most any gasket sealer will do fine. I've used brown brush-on permatex because I like the way it smells and have been using it for 40 years. I have used red silicone because it's what I had. I have used black silicone because it's what a friend had. None have ever leaked.

PM me on the tools.

Tom

Tom

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post #3 of 10 Old 08-05-2011, 10:10 PM Thread Starter
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Thanks for that link, I haven't seen that site yet and it had a pretty good write up on the Doo and what's needed for the change out.
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post #4 of 10 Old 08-05-2011, 10:25 PM
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I have used the stock gaskets dry and never had a problem even after removing and reinstalling 3 or 4 times. If by chance you get Cometic gaskets be sure to use sealer with them.
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post #5 of 10 Old 08-05-2011, 10:26 PM
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Quote:
Originally Posted by SLO-KLR View Post
... If by chance you get Cometic gaskets be sure to use sealer with them.
Oh, hell yes! In fact, make sure you don't get Cometic gaskets.

T

Tom

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte
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post #6 of 10 Old 04-20-2017, 12:06 PM
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I know this is an old post but does anybody out there have the tools available for sale?
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post #7 of 10 Old 04-20-2017, 12:18 PM
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Quote:
Originally Posted by PackyOC View Post
I know this is an old post but does anybody out there have the tools available for sale?
PackyOC, Left click on blue hi-lite,
Anyone need Doo tools?

left click on Sarguy name, send him a PM (private message).

pdwestman
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post #8 of 10 Old 04-20-2017, 12:27 PM
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great thanks!
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post #9 of 10 Old 04-20-2017, 02:35 PM
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For the offset wrench, wouldn't a 1 1/4" or 32mm crows foot work just as well?

Last edited by PackyOC; 04-20-2017 at 02:47 PM.
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post #10 of 10 Old 04-20-2017, 07:17 PM
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Originally Posted by PackyOC View Post
For the offset wrench, wouldn't a 1 1/4" or 32mm crows foot work just as well?
Possibly. Just don't let it slip and damage the rotor magnets!

pdwestman
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