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.

LinkBack Thread Tools Display Modes
post #1 of 5 Old 05-15-2013, 06:44 PM Thread Starter
Join Date: May 2013
Posts: 1
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?
rcm_other is offline  
Sponsored Links
post #2 of 5 Old 05-15-2013, 06:52 PM
4th Gear
Scrapper's Avatar
Join Date: Oct 2010
Location: Deming New mexico
Posts: 1,009

www.eaglemike.com for parts

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

Never ride faster than your angels can fly
Scrapper is offline  
post #3 of 5 Old 05-15-2013, 08:02 PM
5th Gear
Join Date: Jan 2011
Posts: 4,438
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.
Damocles is online now  
post #4 of 5 Old 05-15-2013, 10:39 PM
4th Gear
Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
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 is offline  
post #5 of 5 Old 05-16-2013, 01:03 AM
4th Gear
Scrapper's Avatar
Join Date: Oct 2010
Location: Deming New mexico
Posts: 1,009
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.

Never ride faster than your angels can fly
Scrapper is offline  
Sponsored Links

balancer chain, doohickey, klr

Quick Reply

Register Now

In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Similar Threads
Thread Thread Starter Forum Replies Last Post
Timing or balancer chain noise? 2375 1987 to 2007 Wrenching & Mods 28 10-02-2018 12:22 PM
Cam Chain Tensioner/Timing Question planalp 2008+ KLR650 Wrenching & Mod Questions 21 04-10-2013 03:18 PM
balancer chain adjustment nut all the way tight hiinthesky 1987 to 2007 Wrenching & Mods 5 07-16-2012 05:24 PM
Balancer chain adjustment thumbs 1987 to 2007 Wrenching & Mods 37 06-15-2011 10:22 AM
Aftermarket balancer chain. Johnnieplasma KLR & Other Motorcycle Related Discussion 3 04-20-2010 09:19 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome