Another Doohickey Bites the Dust!! - 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 21 Old 07-26-2007, 06:56 PM Thread Starter
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Another Doohickey Bites the Dust!!

First and foremost, I would like to extend my thanks and gratitude to DaddyJoe for his help and loan of tools. My buddy Frank and I went down to the camp grounds see Joe today and meet him for the first time. We sat and talked for a few minutes, while there I fell in love with "Major" his German Shepherd. That dog is HUGE!! LOL. I have two female German Shepherds of my own, a 3 year old and a 3 month old. Needless to say I have to take my wife down Saturday to see Major.
Anyway on to the rest of the story. We decided that since my bike is still under warranty that we would install the new doo into my buddies 05. The whole procedure was pretty much uneventfull, and I was amazed at the relative easiness of doing this upgrade.
Now for the part we are all waiting on, below you will see a picture of the spring, does something look amiss? It was "broke"! Imagine that, LOL. He had no tension whatsoever on the timing chain. We installed the new spring and the doohickey and got it all buttoned back up. Gaskets remained good, so did not have to purchase the extra ones Joe keeps on hand. He was also gracious enough to allow us to use his wrench.
We are going to head out for a small ride tomorrow after he is finished with the doctor and enjoy a few miles around the mountains of Central Kentucky. Hoping to have some pics of that tomorrow or Saturday.

Heart felt thanks Joe.

The bike has just over 4000 miles on it. It is hard to tell, but it looks like the spring has been broken for some time. There is no fresh shiny material from a recent break.

P1010004.JPG

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #2 of 21 Old 07-26-2007, 07:13 PM
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doohicky?

just got my 08 bout 6 weeks ago, how long befor i need to consider changing mine? got roughly 2000 miles on it.
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post #3 of 21 Old 07-26-2007, 07:19 PM Thread Starter
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One of the MANY upgrades done to the new style 08's was an improved doohickey. The difference between them and the old style like I have is huge. I think the factory finally listened and silently accepted that they had a problem with it, thus it was beefed up. I personally don't think you will have a problem, but in my opinion, if you do, it might turn out to be the spring just like this one, that might be the weak point. Myself, I would probably change it anyway, but that is just the way I am. You still have a years worth of warranty, ride it, then a couple months out from the end, open up the side cover and inspect the doo. If you see an issue with it, change it. Here is a link that shows exactly what we did today.
http://www.klr650.marknet.us/Doohickey.pdf

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #4 of 21 Old 07-26-2007, 07:30 PM
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thanks, ill check it out.
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post #5 of 21 Old 07-26-2007, 08:19 PM
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DX you and I both know all I did was supply the wrench, although I did get to watch and spend an afternnon with two gr8 guys.

I'm not sure the 08 doo has been upgraded, I know I heard the 05-06-07-and now the 08 has been upgraded, but I went through the show me state once, so I'll beleive it when I see it. It seems like every year someone says the new ones has been changed, (salesmen mainly) now the 08's have had several things changed, but has anyone looked inside an 08 to see if it is different?
DX, with two females I'm sure Major would love comming to live with you. I can see plenty little ones in the future.....

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post #6 of 21 Old 07-26-2007, 08:36 PM Thread Starter
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I've got to find the site where someone actually had an 08 lever and showed it up against the older style. But, as we know anything can be accomplished on the net...lol. My wife went all soft hearted when I showed her the pic of Major. We'll have to talk tomorrow.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #7 of 21 Old 07-26-2007, 09:13 PM Thread Starter
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Quote:
Originally Posted by kw08klr View Post
just got my 08 bout 6 weeks ago, how long befor i need to consider changing mine? got roughly 2000 miles on it.
OK, I retract my statement about the new 08's having a better doohickey. They might, but I checked the part numbers of the 08 against the 07 and they are identical, unless they kept the same part number for the improved lever, I would have to assume they are the same crappy design. I still swear I read somewhere that the lever had been upgraded, but maybe I am just wishing instead.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #8 of 21 Old 07-26-2007, 09:25 PM
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Hey guys.
Yes, the doo was definitely upgraded. Eaglemike pulled one & took pics side by side. The new one looks beefy like his but he says that the fit is a little sloppy. He says there seems to be no improvement in the spring.
John

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post #9 of 21 Old 07-26-2007, 09:32 PM
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I have been real active on the forums since I bought my 04 back in May of 04, and every year when the new ones come out someone asks a salesman about the doo and they swear it has been changed.
kawasaki could have changed it this year, but I don't think they want to admit it is bad. It boils down to $$, as long as everyone changes them "after" the warrenty is up Kawasaki doesn't spend any $$ on them, so if they don't spend $$ there isn't a problem.
I'll have to call eagle Mike to find out if it has been changed, I think he would know.

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post #10 of 21 Old 07-26-2007, 09:33 PM Thread Starter
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Sounds like a person would still be prudent to do the doo on 08's especially with the better torsion spring mod.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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