just rebuilded the 1990 kawasaki klr 650, during the inspection of doohickey i found that the spring that holds the Doo has no tension at all, and the screw that holds the doohickey is at the end of it. The doohickey seems fine. When motor is running i can hear the noisy chain sound in the left side of engine. The question is, is it possible to add more tension to the doohickey, or i this is the end of the chain sprockets?
When you say the bolt that holds the doohickey is at the end of it, do you mean the doo is rotated fully clock wise or counter clock wise? Is the bolt at the right end of the slot in the doo or the left end?
If it is at the right end, there is no more adjustment range left in the doo and most likely the rubber shoulders on the sprockets are compressed or worn down. This usually happens before the chain wears out. How many miles ore on the KLR?
BALANCER CHAIN LENGTH SPEC says it should be replaced when the 20 link/21 pin length reaches 193.4 mm:
New 20 link length is 190.5mm
On my 2008 KLR at 97,000 miles length =191mm a long way from worn out.
The chain rides on the rubber shoulders of the sprockets and if the rubber is not torn up, just compressed by the chain side links, you can get some adjustment range back by re indexing the chain around one link on all the sprockets without moving the sprockets. I regained half an inch of adjustment by doing this.
The re indexing by one tooth causes the outer links to hit on uncompressed rubber next to where the inner links were before and the inner links hit next to where the outer links were before. If the rubber is torn up, you will need some new sprockets. It is important to keep all the sprockets properly indexed on their shafts and move the chain one tooth on all the sprockets including the crankshaft sprocket so the balance timing is not changed.
Helpful info here: MarkNet - KLR650