Dodged a bullet with the 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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  • 1 Post By Kurt V
  • 3 Post By pdwestman
 
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post #1 of 5 Old 12-16-2019, 08:28 PM Thread Starter
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Join Date: Oct 2019
Location: Lincoln,NE
Posts: 13
Dodged a bullet with the Doohickey!

Or should I say the Doohickey spring. Either way, my 1999 KLR, with 23,000 miles, was due for some upgrades. Specifically the Doohickey and the Thermo Bob 2. The original Doohickey was still in good condition. Canít say as much for the spring. One end was broken off. Both projects went without any drama. YouTube was definitely my friend with both projects!
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post #2 of 5 Old 12-17-2019, 11:44 AM
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Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,204
OEM doo

When looking at the oem doo-hickey one can usually see evidence of number of times adjusted by the marks or stains in/on the metal surfaces of the adjustment slot.

Did you by chance leave the locking bolt tight until the outer cover & flywheel were removed?
If so how sloppy was the chain?

Had the oem doo ever been allowed to adjust? Or was there only the 1 bolt mark?

I realize / hope you realize that pics, links, vids are allowed after 15 postings as anti-spammer measures.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 5 Old 12-18-2019, 04:33 PM Thread Starter
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Join Date: Oct 2019
Location: Lincoln,NE
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I did leave the Doohickey bolts tightened up when I remove the cover. Looking at the stock Doohickey you can see marks from where it was originally installed. Doesn’t appear to ever have been adjusted. I also examined the chain before I remove the bolt. It appeared to be fairly snug.
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post #4 of 5 Old 12-18-2019, 07:17 PM
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Join Date: Nov 2009
Location: Lander, Wyoming
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Just so that you have a better understanding of the balancer chain system, I'll offer this.

If the engine is coming Up on compression stroke when the key is turned OFF, the crankshaft may rotate Backwards a bit. This can place the balancer chain slack on the wrong side of things to properly re-tension the chain by simply loosening the locking bolt.

My best advice is to always remove the 2 plastic plugs on the LH flywheel cover and using a 19mm socket, turn the engine CCW to TDC mark before attempting to allow balancer chain adjustment. This will allow the spring to remove all of the balancer chain excessive slack.
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 5 Old 12-19-2019, 09:05 PM
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Join Date: Mar 2019
Location: So. Cal.
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Garage
PDW, thanks for that TDC tip. Makes total sense. The Gen II I picked up this year only has 4500 mi. and has not been adjusted yet. When I do Iíll be sure to rotate to TDC.
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