Doohickey Question (idler gears) - 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 24 Old 10-02-2016, 11:54 PM Thread Starter
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Doohickey Question (idler gears)

Hey all,

I am in the middle of a doohickey swap, luckily I found a local with some tools, and a shout out and thanks to Sarguy for offering his up to me! Anyway, I have a few questions. I drilled out the torsion spring hole and scrapped off the old gasket, and just cleaned the heck out of the case cover. IN doing so I cleaned out the lube in hole that the idler gear shaft sits. My question is what do/would you guys relube it with? Is engine oil enough? The clymer says to use some moly, well the only moly lube at NAPA was some valvoline moly fortified grease and when I got home I realized that it didn't mention anything about being used for engines. Should I find some assembly lube? Am I over thinking this? This very well could be the case, I tend to try and follow directions to the T.

Welp, thanks all

Pete
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post #2 of 24 Old 10-03-2016, 05:09 AM
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I sure got lucky it sounds.

I did nothing at all other than dropping them in place, switching them so they fit right, and
buttoned the case back up. Runs perfect 20k later.

Got lucky by doing it to a new engine also from what prep you had to do. I was able to reuse
the gaskets. Take apart, remove stuff, add stuff, bolt back together, ride. laid the bike on it's side
and didn't lose any oil !! Probably took all of an hour.

This is my son, with whom I am well pleased." ----God
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post #3 of 24 Old 10-03-2016, 08:47 AM Thread Starter
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Yeah, I had purchased a gasket just incase and I figured while I had the tools I might as well put a new gasket so I wouldn't have to borrow them again to fix a leak. But yeah its really not that bad of a job.
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post #4 of 24 Old 10-03-2016, 08:53 AM
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Going to be doing this soon on my 87. Do you guys recommend the torsion spring over the newer dual eagle mike springs? Or do you think either will be fine for daily riding. Thanks!
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post #5 of 24 Old 10-03-2016, 10:13 AM
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Going to be doing this soon on my 87. Do you guys recommend the torsion spring over the newer dual eagle mike springs? Or do you think either will be fine for daily riding. Thanks!
The torsion spring is a superior design and installing one means you won't need to periodically replace the spring with one the right length as the system wears. Either will work just fine but the torsion spring is a one time thing.


Dave
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post #6 of 24 Old 10-03-2016, 05:05 PM
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Originally Posted by Hamman View Post
Going to be doing this soon on my 87. Do you guys recommend the torsion spring over the newer dual eagle mike springs? Or do you think either will be fine for daily riding. Thanks!
Replacing the doohickey after nearly 30 years?

Bayesian probability says, you're probably good to go, as-is!

No guarantee, but agree--if you're gonna do it, the torsion spring design is superior (have it on my '07).
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post #7 of 24 Old 10-03-2016, 08:05 PM
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Replacing the doohickey after nearly 30 years?

Bayesian probability says, you're probably good to go, as-is!

No guarantee, but agree--if you're gonna do it, the torsion spring design is superior (have it on my '07).
Damocles,
I'll dis-agree!
Even after 20-30 years of wrenching on motorcycles, I managed to Over-Torque the lock bolt of the doo-hickey on my personal 1987 KLR650, because of 'trusting' my educated right hand.

69-87 inch pounds is just so easily "over-Done" it ain't funny!

To the OP, do the EM Doo-Hickey with the Newest Torsion Spring, and never have to look back.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #8 of 24 Old 10-04-2016, 08:12 AM
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Originally Posted by Damocles View Post
Replacing the doohickey after nearly 30 years?

Bayesian probability says, you're probably good to go, as-is!

No guarantee, but agree--if you're gonna do it, the torsion spring design is superior (have it on my '07).
Haha, ordered it to be safe. Actually just picked the bike up. Haven't even heard it run yet. Got a ton of work ahead of me. I ordered the torsion spring design. Looks proven to be more reliable. Thanks
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post #9 of 24 Old 10-04-2016, 09:26 AM
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I have a 2005 KLR 650 with 19,000 miles that I recently purchased. The previous owner did not address the "doohickey" and was uncertain if the original owner had either. Is there any way to determine if the repair has been made without disassembling and visually inspecting? I suspect there is not but I figured I'd ask just in case.
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post #10 of 24 Old 10-04-2016, 09:40 AM
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You will at least need to take the left side cover off to peek at the doohickey.

Not a big deal but it could involve a new gasket, so best to have one on hand.

There's a video that goes into how to tell the difference. If you are interested I'll post a link to it.

Tom

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