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 11 Old 05-01-2020, 05:09 AM Thread Starter
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Doohickey

Hi all, today is my doohickey day. I have watched the videos, Tom’s Superdoo and others. I have spoken to people that have done this replacement. Looks like I can expect anywhere from a solid 45 mins to up to 2 hours. I have written down Tom’s steps and will have his videos present. The big lingering question I have is, what are the torque specs for the inner and outer case bolts? I see the doohickey bolt is 78 in/lbs is this the same for all of the bolts? Other than eagle mike kit with tool and a 19 mm, 8 mm sockets, breaker bar, and 1/4” and 1/2” drive torque wrenches do I need anything else. I plan on having a few small disposable plastic containers for the fasteners, rags and new oil on hand. Thanks. Side note I have searched the internet and have found a torque spec sheet but nothing about the case bolts.
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post #2 of 11 Old 05-01-2020, 06:07 AM
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Check out the torque values available here: Sorry, that's copyrighted material

Last edited by klr4evr; 05-01-2020 at 11:05 AM. Reason: Link to copyrighted material removed.
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post #3 of 11 Old 05-01-2020, 06:08 AM Thread Starter
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Awesome thanks
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post #4 of 11 Old 05-01-2020, 11:05 AM
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Sorry. Link to copyrighted material removed. The forum places itself in jeopardy as an accessory if it allows copyrighted material and links to copyrighted material to be displayed.

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post #5 of 11 Old 05-01-2020, 11:42 AM
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The torque spec for the case bolts is only 69inch-lbs. Inch with a capital "I". I am reminded of a long-ago posting on the old Yahoo Groups by a guy who claimed to be an experienced mechanic. In his post, he was going on about what poor quality the Kawasaki case hardware was. He busted three of them in a row before even getting to the torque value, so he lowered the setting on his wrench a bit and busted three more.

He was using a 3/8" torque wrench calibrated in foot-lbs.

I use an electric screwdriver to speed up disassembly and reassembly. It will torque stuff down to 40 inch-lbs. I set my torque wrench at 65inch-lbs.

Another tool I recommend is a flexible magnet. In the videos, there are cautions about dropping the washers in the hole and a procedure to prevent it but it is better to have a flexible magnet on hand and not need it (because you were smart and paid heed to the dire warnings) than need it and not have it.

Something similar to this is a Good Thing®:V8 Tools, Inc. On-line Catalog

It has a nice small head on it and is stuck on the end of a wire. Anything like this that is available locally is good.
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post #6 of 11 Old 05-01-2020, 01:07 PM Thread Starter
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Thanks guys. Doohickey is all done. I had a little hiccup. When putting the little dent in the woodruff key, I hit the awl. When I did the woodruff key disappeared. Called around, ended up getting one from a local machine shop. When I got back home it magically reappeared. All said and done it was great and the videos From Toms superdoo were extremely helpful. My tensioner spring was broken. The chain was slack. There didn’t appear any damage on the inside of the case. I didn’t realize how crappy my bike sounded until I heard what it sounded like after the replacement was done. I am very happy I did this upgrade. Thank you to all with the tips.
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post #7 of 11 Old 05-01-2020, 02:44 PM
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Tom [email protected]

“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #8 of 11 Old 05-01-2020, 04:03 PM
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Quote:
Originally Posted by Donkey View Post
Check out the torque values available here: Sorry, that's copyrighted material

Oooops! Very sorry!
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post #9 of 11 Old 05-01-2020, 04:44 PM Thread Starter
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Nice video there and no worries about the torque values. It’s all good now. Thanks though.
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post #10 of 11 Old 05-03-2020, 06:39 PM
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Cslang, curious what year is your bike? My 2014 Gen2 I picked up last year just hit 5K mi. so I popped the Doo adjuster plug and found the bolt was totally lose. I torqued it to spec but now I’m worried what’s happened inside there. Ordered all my Doo parts and tools today. I’ve never heard any odd noises or scraping sounds and nothing in the oil so hopefully no damage. Thx.
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