after reading so much about the doohickey failure issue, its hard for me to believe that kawasaki hasnt redesigned the part after all the years of trouble, you would think how a company of that magnitude, could be onboard with consumers seeking aftermarket answers to a chronic mechanical failure issue, anyways nice to know the public has addressed and fixed the problem.
Actually, mayor4u, Kasasaki DID redesign the doohickey, released with 2008 models.
Since (six model years, 2008-2013, inclusive), I am unaware of a bonafide single doohickey component failure (idler shaft lever, apart from separate spring tension issues). [Contrary direct perception experience, observation, and, one hopes, images, welcomed!]
I post this at considerable risk of precipitating controversy and banning from the forum. I do not doubt that one or more doohickey failures has occurred after the advent of the 2008 part upgrade. As a minimum, I believe it's fair to say the failure rate of the latter-day doohickey, if any, is dramatically less than the older part.
Yet, many passionately, and I think honestly, believe EVERY stock doohickey, regardless of vintage and design, exists as an insidious ticking time bomb caclulated to destroy its host KLR650 engine, sooner or later.
Aftermarket doohickeys doubtless have better fit, finish, and greater adjustment range than any corresponding OEM part. Yet, from published comments, the maintenance history of the '08-and-later stock doohickey appear dramatically different from the previous stock components.
Now, may the flaming begin!
CAVEAT: Aftermarket doohickeys, AFAIK
, are well-designed, competently manufactured, and responsibly marketed. Nothing "wrong" with such an "upgrade," IMHO.
FULL DISCLOSURE: I have an aftermarket doohickey and torsion spring installed in my Generation I KLR650.