Join Date: Sep 2006
Location: Riding around the USofA
The "doohickey" it the counter ballancer lever. Yes it is a cheap part Kawasaki puts in the KLR, about 1/3 of the KLRs wind up with a broken doohickey in the first 10,000 miles. Some cases have been reported that the pieces have locked up the motor by getting caught in the chains.
Kawasaki refuses to admit there is a problem, and my guess is because it costs them no money, they don't want to admit there is a problem. Most people change them out without Kawasaki's knowledge. Yes it is the same piece of crap on the 07 s.
A guy "Eagle Mike" in San Daigo CA makes a replacement lever that is top notch. He sells them for around $40, and it takes about two hours for the novice mechanic to change one out. Several people have posted directions on how to do the doo.
Today is the first day of the rest of your life.