2003 KLR 650 Balancer Chain Tensioner Question/Help - 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 5 Old 05-15-2013, 06:44 PM Thread Starter
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2003 KLR 650 Balancer Chain Tensioner Question/Help

Just bought another KLR. I had one a few years ago (2003 KLR 650) and the balancer chain broke and wrecked the engine at about 40,000. I put on about 8,000km of the 40,000. I had just adjusted the bolt (like the manual says) and about 500km later the balancer chain broke - end of bike. Now I have another 2003 KLR 650 with only 16,000km on it. Runs great, no problems. I changed the oil/filter after buying it and took it to a Kawasaki dealer (in France) just to ask more info. They didn't seem to know what the balancer chain tensioner was and said they never touch it. Seems a little odd, since I read all over these forums of people talking about this. I don't know if the last KLR was just bad luck (I kept up with all the maintenance) or what, but I'm worried. I'm getting ready for a long trip and am wondering what I should do. I'm in France, so not sure I could get some after-market parts for it and not sure how difficult it would be to install the improved kit. Any thoughts, advice?
Thanks
Robert
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post #2 of 5 Old 05-15-2013, 06:52 PM
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www.eaglemike.com for parts

it's a simple fix that can be done in an afternoon of tinkering. definately do it

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post #3 of 5 Old 05-15-2013, 08:02 PM
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While there are similarities, "Jurgen" is working on a Generation 2 in the video above; Robert (rcm_other) has a Generation 1.

As I perceive the video, Jurgen had a SPRING TENSION issue, not a DOOHICKEY (idler shaft lever) problem. Merely replacing the tension spring with one having proper elasticity should have cured Jurgen's problem.

Upgrade of Generation 1 doohickeys appears sound maintenance to me, since the factory part's strength and durability have proven marginal. Further, component failure of the doohickey can cause catastrophic collateral damage to the engine, as previously experienced by Robert.

If practicable, Robert, upgrading your doohickey (ideally, with torsion spring) seems a good idea to me. If not . . . most KLRs operating on the planet today muddle through with stock doohickeys, I'd imagine.

So, the decision to launch with a factory doohickey remains probabilistic; the odds of a malfunction or not remain what they are.

So, do you feel LUCKY? Your call!

Last edited by Damocles; 05-15-2013 at 11:32 PM.
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post #4 of 5 Old 05-15-2013, 10:39 PM
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If you are planning on riding for any distance or going on any adventure and you haven't at least had a look inside to check what's what, then....what can I say? It is an easy job to open both side cases to have a peek. It may be a total waste of time but it also could be an engine saver! Also check the valve shim clearances....it's just a way to assure you will hopefully have a safe and non eventfull trip. I would be all over that engine and bike to make damned sure it's in 100% the best possible shap it can be.
Just saying.....it's easy now, where you have access to tools and help possibly which is much better in the middle of nowhere with nothing.

Open it up or find a shop who can help and not just say ride it until it blows....??????

Willys
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post #5 of 5 Old 05-16-2013, 01:03 AM
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sorry didnt watch the video, assumed he did the torsion spring. but yes do the doo with an eagle mike torsion spring. dont cheap out like we klr riders seem to do and buy from someone else because it's cheaper. get the eagle mike stuff.

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