Dohickey question - 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 14 Old 08-08-2007, 10:38 AM Thread Starter
 
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Dohickey question

I just bought a 98 with about 9k miles. I am apparently the 3rd owner. The last guy had it around 1 1/2 years and only changed the oil. I am curious if there is any way of verifying weather or not the dohickey has been upgraded or replaced, aside from taking it apart? Also are there any warning signs that might tell me that its already broken?
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post #2 of 14 Old 08-08-2007, 10:54 AM
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Only way to know is to take it apart. My buddies 05 had the spring broken, which was not putting any tension on the cam chain tensioner, and there was not really any indication of a problem, although he says now it feels smoother, and maybe does not rattle as much.

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post #3 of 14 Old 08-19-2007, 05:58 PM
 
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Wouldnt it just be easier for Kawi to use a tensioner like the EX500 has on it? I mean really that would work out just as well if you asked me, although it'd probably entail redesigning the cases a little bit.
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post #4 of 14 Old 08-01-2008, 09:09 AM
 
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Noob here with 1st stupid question: did Kawi fix the dohickey with the 2008's or is it still an issue?
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post #5 of 14 Old 08-01-2008, 12:07 PM
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Doo Hickey

The doo is still aproblem on the 08
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post #6 of 14 Old 08-01-2008, 12:46 PM
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Direct post from the man that makes the doohickey replacements:

Quote:
Originally Posted by eaglemike1 View Post
For all the people that say the 2008 setup is the fix - how many have been into how many engines?

It's an interesting situation with the 2008 lever. As we all know, Kawasaki dealers have always said there was never a problem, right? And now they fixed the (non)problem, right? Well, sort of.... The 2008 lever probably won't break. Does it fit well? No...... Will the spring break? No..... Will the spring adjust the slack out of the system?? Not a chance after the first adjustment, and sometimes not even then. The factory spring is far longer than any of the previous versions. The chain and sprockets are the same as before. The location of the parts in the engine is the same. They beefed up the wire diameter so it won't break, and made it too long to work. This is objective fact. A lot of 2008 owners have change out the parts and reported a smoother and quieter engine. Bottom line - the 2008 parts won't destroy your engine, but they don't work properly either. The loose fit of the 2008 lever will have long term effect.

Below is a pic of my 2008 spring at 327 miles. For those that haven't been into the left side, it's supposed to hook over the peg you can see at the left end of the spring. The spring has actually slid to the right slightly, so you can see there would not be any tension on the spring.

I do make the aftermarket parts. I'm confident if I put the parts in your hands, and could share my experience with you, you'd reach the same conclusion.

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Previous ride was a 2007 KLR Black/Silver, I miss it..
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post #7 of 14 Old 08-01-2008, 03:45 PM
 
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Quote:
Originally Posted by DXKLR View Post
Direct post from the man that makes the doohickey replacements:

Thanks for the info. Perhaps they'll tackle the spring in the 09 model year. Hell, at this rate it should be perfect by 2030 or so.
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post #8 of 14 Old 09-26-2010, 05:43 AM
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that was my next question did they do anything different to it on the 09 models? I have one with a round 400 miles on it (only had it 4 days ) and would like to know if I need to change it out at first service
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post #9 of 14 Old 09-26-2010, 06:57 AM
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Quote:
Originally Posted by lambo84 View Post
that was my next question did they do anything different to it on the 09 models? I have one with a round 400 miles on it (only had it 4 days ) and would like to know if I need to change it out at first service
The Balancer Idle Lever, or doohickey, on the '08 and newer bikes is of different design and manufacture than the pre-'08's. I haven't seen nor heard of a lever failure on the '08 and newer models. The spring that attaches to the balancer lever is not up to the task, and should be replaced. Not an issue requiring immediate attention, but something I would consider before the doohickey requires adjustment, which is done manually. Between adjustments, the spring does not do squat.

Here is some information about that spring from the Godfather of Doohickey's:

http://www.topgunmotorcycles.com/ti_...e/tiapr09.html

Top Gun has a replacement spring available, as well as entire kits with inspection ports.

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post #10 of 14 Old 09-26-2010, 07:17 AM
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Lambo,

Mine got changed out at 1244 miles. Everything was in fine shape, but the
spring indeed, had no tension on it. There was not even room for the first adjustment.

No hurry, but don't put it off for thousands of miles either.

This is my son, with whom I am well pleased." ----God
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