Doohickey? - 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 16 Old 08-26-2009, 11:48 PM Thread Starter
 
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Doohickey?

This part seems to cause a lot of problems but I don't know what it is and what the problem is. Please fill me in. Thanks.
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post #2 of 16 Old 08-27-2009, 12:00 AM
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post #3 of 16 Old 08-27-2009, 12:01 AM
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post #4 of 16 Old 09-27-2009, 05:46 PM
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If I read the instructions correctly, when I order parts for my doohicky upgrade, I will need the replacement dh, new spring/springs (either torsion or regular), probably the two new housing gaskets, and a torsion bolt?
Tool wise, just the "special wrench" for the torsion bolt, and a torque wrench?.... along with all the "normal" hand tools/wrenches, etc...

Does that sound about right? I see the potential for an "all items included package" from Eagle Mike. (at a discounted price, of course)
Unless, of course, he already offers one... I need to go check out his website.
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post #5 of 16 Old 09-27-2009, 05:55 PM
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The housing gaskets (knock on wood) alway come off in one pc. if you take the cover off carefully... We typically give the old gasket a light film of RTV before putting it back on.. We've had a spare gasket laying around since the beginning and have never needed it.

Tools are available, usually for the asking and the price of shipping from someone who's done the doo.. This includes the wrench and torsion bolt..

I'd recommend putting out a post to see if some in DFW area has tools and would be willing to assist.. You'll need the doo and springs (either torsion or regular) and it's a good time to change oil since draining oil makes less of a mess. Basically, you'll need $40 worth of parts, and someone local who's done it before, as well as some borrowed tools..

As far as a torque wrench, hit up Harbor Freight and pick up a cheap one.. Good thing to have on hand, anyway.

We typically do the Doo, and also replace subframe bolts at the same time, but the bolts can wait.. Not sure if the 09' has an issue with subframe bolts, but the pre-08' models could use the better hardware if you're hauling a passenger or have bags or a top box. Basically, cheap insurance..
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post #6 of 16 Old 09-27-2009, 06:36 PM
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I've got a couple of Proto torque wrenches... I'm not sure if the "big" one goes up to 100+ pounds or not, though.

I thought about fabbing my own wrench.. what is it, a 28mm, or some such?

I might just try it without the new gaskets.. it would sort of suck if they tore up, and I didn't have any to replace them with, though. Another week long wait.. although I guess the Stealership might stock them.
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post #7 of 16 Old 09-27-2009, 06:56 PM
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Yeah, I think 28mm, or 1 1/4" will work, too.
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post #8 of 16 Old 09-27-2009, 08:07 PM
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El Cheapo' made in India (Poonjab?) 1 1/4". Torch, vise, hammer = instant special tool.

My gaskets came off clean and were reused. No leaks after 2,000 miles.


Gray-haired riders donít get that way from pure luck.

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post #9 of 16 Old 09-27-2009, 11:37 PM
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Quote:
Originally Posted by flash View Post
El Cheapo' made in India (Poonjab?) 1 1/4". Torch, vise, hammer = instant special tool.

My gaskets came off clean and were reused. No leaks after 2,000 miles.

Yes, that is exactly what I was thinking. Pawnshop tool, oxyacet torch... yee haw.
POON-jab? I'm not even gonna TOUCH that one...
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post #10 of 16 Old 09-28-2009, 12:04 AM
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hornetguy,

Since you live in a larger city you might want to put a Tech Day together and get some assistant / support from other(s) that have already completed the upgrade. Tech Days are usually a fun event and you get to meet other KLRistas. Plus they can bring their tools and you don't have to make them.

Do yourself a favor and buy your parts from EagleMike, the guy that makes the Doohickey and supporting parts. He also sells the other items needed for the upgrade. Or load your stuff up and come to the Julian CA (SoCal) Tech Day on October 10th. You wouldn't be the first person to show up from east of CA.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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