doo-hickey questions - 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 9 Old 08-14-2010, 08:50 AM Thread Starter
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doo-hickey questions

I just purchased a 88 650 with 7000 miles on it. No Mods. How is the "doo" on this model? Should it be changed? Where is the best place to get the parts and necessary specialty tools? Got directions? Thanks in advance!!!!!!!

This site is awsome.

Getting ready to do the $.22 mod. Can't wait!!!!
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post #2 of 9 Old 08-14-2010, 09:43 AM
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Any -07 models should have the doo changed as soon as you can. The lever on those models are a welded two piece design and are the worst as far as having the potential to fail. Best place to get all that you need to perform the task is from Eagle Mike. http://eagle-m-e.com/
The best that I have found for blow by blow direction are those that are printable from Happy Trails' web page. They are very well written and illustrated. http://www.happy-trail.com/pdf/KLR650-doohickey.pdf
Have fun.

Stephen
2009 KLR 650
2008 GL1800
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post #3 of 9 Old 08-14-2010, 09:46 AM
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http://klr650.com/Doohickey.htm

Here is one option. I list them first, because they do this:

http://klr650.com/Links.htm

I try to live in a world where one hand washes the other.

Here's another outfit that sells parts and kits. My experience has been very good with them.

http://www.tpimotorcycleparts.com/

I find this process of upgrading the counterbalancer idler shaft adjustment lever components interesting. Allows you to visually inspect the doohickey without pulling the engine cover. Link below.

You might read up on some shared wisdom from one of the pioneers of doohickey replacement, Eldon Carl:

http://www.topgunmotorcycles.com/ti_...e/tiapr09.html

http://www.topgunmotorcycles.com/FFT/fftoct09.html

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
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post #4 of 9 Old 09-03-2010, 06:10 PM
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Just did the 22 cent mod today .Was really nervous about going at carb.But boy sure glad i did. Googled and found pics which really helped.Better throttle response starts way better and 95 % less popping.Amazing difference.Also removed snorkel.
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post #5 of 9 Old 09-05-2010, 12:27 AM
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Good deal, Shadowdude!

You are just taking back what the EPA stole. These
engines aren't excactly power monsters, but some
basic changes really wake up what has been compromised
to meet emissions requirements. If everything's done
correct and careful, mileage will stay the same or even
slightly improve. Less gas = less emissions anyway.

I did the .22, removed the snorkel, and opened the stock
exhaust for a freer breathing, responsive, and very fun motorcycle.

Cheapdude

Thanks Vat for the useful info in the linx. U rock as usual for doing
homework and digging up the stuff the guys need.

This is my son, with whom I am well pleased." ----God

Last edited by CheapBassTurd; 09-05-2010 at 12:30 AM.
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post #6 of 9 Old 09-16-2010, 07:17 PM
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doo-hickey

So, what would happen if the doo-hickey failed? I have an klr650 05 with 2500 miles and I havent replaced it yet.
Thanks, Tom
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post #7 of 9 Old 09-16-2010, 08:04 PM
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Well, just depends. If the balancer lever [doohickey] breaks into pieces, and or the spring breaks and is running loose, those pieces can get into the balancer chain and lock things up tight. They could drift with the oil flow into the crankcase / oil sump, which is shared with the transmission. Doohickey metal pieces in the gears = catastrophic failure.

Here's some write ups from one of the guys who pioneered the doohickey replacement. This guy has been rally racing since 1955, has put over a quarter of a million miles on KLR 650's, a lot of it two up running in rally's. Top Gun / Multisurface Motorcycle sets up rally and 'round the world bikes. They know how to do reliability.

http://www.topgunmotorcycles.com/ti_...e/tiapr09.html

http://www.topgunmotorcycles.com/ti_...e/tijan07.html

http://www.topgunmotorcycles.com/ti_...e/tiaug07.html

http://www.topgunmotorcycles.com/ti_...e/tijan08.html

Maybe nothing will happen. Maybe your balancer chain will last and last without adjustment. Or maybe your engine / transmission will lockup at 70 MPH, locking the rear wheel. That'll be a ride you won't soon forget. This is not a requirement to have a full and meaningful riding career.

Not every balancer lever [doohickey] breaks. Not every spring breaks. The problem is, we don't know which ones will be OK, and which ones could grenade in the next mile. Your bike, your ride, your call.

******
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[/I]
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post #8 of 9 Old 09-16-2010, 10:58 PM
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Quote:
Originally Posted by vatrader View Post
Not every balancer lever [doohickey] breaks. Not every spring breaks. The problem is, we don't know which ones will be OK, and which ones could grenade in the next mile. Your bike, your ride, your call.
Parts are $40 and it's cheap peace of mind..

I changed mine 4 years ago, and it was fine, but I've personnally seen 6 that weren't.. 4 bad springs, 2 bad doos..
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post #9 of 9 Old 09-17-2010, 08:13 AM
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Quote:
Originally Posted by TomJ View Post
So, what would happen if the doo-hickey failed? I have an klr650 05 with 2500 miles and I havent replaced it yet.
Thanks, Tom
This engine had been run for many miles with a broken Doo, the balancer chain was slack and very noisy. The Doo was replaced but the chain had been stressed and after very few more miles, the chain let go. The balancer chain caused the cam chain to skip and the result was 2 bent intake valves. Luckily there was no case damage.
Chain, guides, valve job etc was several hundred dollars.
It's a "pay me now or pay me more later deal"
Do the Doo!


BTW, no second hand info here, that's my '03 engine

Don H
Spring Valley AZ
'03 KLR 650/DS sidecar
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