08 doo hickey - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 5 Old 02-01-2011, 10:49 PM Thread Starter
1st Gear
Join Date: Nov 2008
Posts: 21
08 doo hickey

So I finally got around to upgrade with eagle mikes doo hickey. After 15000 miles there was absolutely no tension on spring. The problem I noticed was that after the new spring was installed ,there was only about. 005 of an inch between the balancer chain and housing at the bottom of idler gear.It was the same with either spring. Has anyone run into this?
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post #2 of 5 Old 02-02-2011, 07:45 AM
5th Gear
Join Date: Sep 2006
Posts: 4,700
Hang onto that thought.. I'm going to page Eagle Mike to have him answer it. He's got more experience than anyone else I know on the matter..

The one thing to remember is that if the chain is tight, the spring can't make the distance any less. It could be a casting or machining issue from Kawasaki??
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post #3 of 5 Old 02-02-2011, 08:49 AM
2nd Gear
Join Date: Oct 2006
Location: SoCal
Posts: 103
This isn't too unusual. Since the chain has been running with slack for a while, there has been more wear on the chain and sprockets than there would be with a properly tensioned system.

There's a couple of ways to address this. One is to do nothing. Eventually the chain will hit the case in this area (the bolt boss cast into the case). Just let it wear in and let the filter catch the aluminum. The amount would be quite small. You could also clearance the case a bit. Remove the idler sprocket, shaft, bearing, washers, stuff the hole in the case with paper towel. Mask the area like a dentist doing a root canal. Use a very sharp chisel and CAREFULLY remove material. Some have used a dremel, but this creates enough dust it's hard to catch it all, and takes about 3 oil changes to flush all the aluminum. The "let it wear" method puts less aluminum into the oil.

You could also get a new/better condition used chain and sprockets from eBay or the dealer. Measure the chain according to the specification in the manual - the spec is found in the top end section of the older manual and I think the same place in the new manual, adjacent the cam chain spec. In my experience changing the sprockets will get it back to normal - but measure the current balancer chain to be sure. The chain is expensive new, the sprockets slightly less.

Hope this helps.....
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post #4 of 5 Old 02-02-2011, 01:49 PM Thread Starter
1st Gear
Join Date: Nov 2008
Posts: 21
Thanks for all the input! I filed enough of the housing to give it about .030of an inch and it worked like a champ.Believe it or not,the engine does sound more quite.
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post #5 of 5 Old 02-04-2011, 04:52 PM
1st Gear
Join Date: Mar 2010
Location: Van Buren, Arkansas
Posts: 52
When I changed my doohickey on my '09 there was no tension left in that spring and it only had about 3k miles. I couldn't believe it. I installed the torsion spring with my new doohickey and it sounded like someone had pushed the mute button when I fired the engine up. Unbelievable how much quiter it was.

2009 KLR 650
2008 GL1800
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