The Doohickey got fixed on the Gen2 bikes, right? Ah, but the spring, the spring.... - 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 76 Old 02-19-2013, 06:40 PM Thread Starter
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Arrow The Doohickey got fixed on the Gen2 bikes, right? Ah, but the spring, the spring....

That seems to be a common question, so here's one answer.


T

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Last edited by Tom Schmitz; 08-15-2013 at 10:49 AM.
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post #2 of 76 Old 02-19-2013, 06:46 PM
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Very nice, Tom. That about says it all.

I predict you'll still see lots of the same questions AND hear a sad, sad story from a stranded Gen II rider.

Good post.
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post #3 of 76 Old 02-20-2013, 02:07 AM
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Maybe the doohickey (not the spring) DID get fixed!

Quote:
Originally Posted by Tom Schmitz View Post
That seems to be a common question [Did the doohickey get fixed on Generation 2 bikes?], so here's one answer.
Seems to me the video clip addresses a TENSIONER SPRING PROBLEM, in contrast to a doohickey (idler shaft LEVER) problem.

The distinction between spring and lever may be a fine one, but . . . the stock Generation 2 doohickey lever shown appeared to be in servicable condition. Rather, a slack tensioner spring appeared to be the deficiency.

An aftermarket coil spring, or a "torsion" spring (the latter with a Moto-Tooled notch applied to the stock doohickey) can be used with an OEM doohickey.

Thus, seems to me what we have here exhibited is a slack tensioner spring, in contrast to a failed doohickey.

Generation 1 doohickeys (the levers themselves) sometimes failed with catastrophic collateral engine damage. Evidence of any failed Generation 2 doohickeys (the levers, not the springs) remains scarce and elusive, I think hardly illustrated by the video clip above of a slack tensioner spring.

FULL DISCLOSURE: An Eagle Mike doohickey (with its superior fit, finish, and extended adjustment range) and torsion spring grace my Generation 1 KLR650!

Last edited by Damocles; 02-20-2013 at 02:21 AM.
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post #4 of 76 Old 02-20-2013, 02:38 AM Thread Starter
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The colloquial question "They fixed the doohickey on the Gen 2, didn't they?" is meant to convey the hope that finally the balancer chain tensioner is something we no longer need concern ourselves with.

I look at the "balancer chain tensioner" as a system. Were the spring easily accessible without removing the the rotor and inner case I might not see it as a system, but as two separate components.

Whether it is the lever that fails (Gen 2 ones don't) or the spring that fails, the end result is the same. At a minimum (and likely most commonly) the chain loses tension, makes noise, and annoys. At a maximum (and likely very rarely) stuff get's loose inside the engine and munches on things.

If either fails the rotor needs to come out, and if the spring fails the inner case needs to come off. Failure is not limited to breakage, but includes ceasing to function due to a poorly specified part (too long a spring).

The point is often made that "they fixed the doohickey!". They redesigned the lever, yes, but it's all the more aggravating that a good adjuster lever is let down by a bad spring.

In my mind, then, they didn't "fix the doohickey".

Your point is well taken, though, Damocles. I shall modify the title a bit...

T
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“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

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


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Last edited by Tom Schmitz; 02-20-2013 at 02:53 AM.
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post #5 of 76 Old 02-20-2013, 04:03 AM
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Just to add, although the gen2 lever is now machined and not welded, it fits sloppily on the shaft, allowing for excessive movement from vibration possibly causing premature spring failure, even aftermarket ones. The only true fix is to replace both with genuine Eagle Mike parts!!
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post #6 of 76 Old 02-20-2013, 08:02 AM
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Quote:
Originally Posted by Damocles View Post
Seems to me the video clip addresses a TENSIONER SPRING PROBLEM, in contrast to a doohickey (idler shaft LEVER) problem.

The distinction between spring and lever may be a fine one, but . . . the stock Generation 2 doohickey lever shown appeared to be in servicable condition. Rather, a slack tensioner spring appeared to be the deficiency.
In my mind it's the same thing. Lever or spring. It don't matter. If either one fails then it's a problem. It's all part of the doohickey.

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post #7 of 76 Old 02-20-2013, 09:01 AM
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I agree and it's just nit picking to try and say one part of the system is good to use when if one part goes bad, the concequenses can be very bad!

I just don't see the need for this arguement? It has been around now since 08 and we all know what is what......why do some still try and defend a known issue?

Just fix it and move on.....simple....why argue for arguement sake?

We all know what the fix is, an Eagle Mike DOO and either the straight spring he supplies in the DOO kit or the better Torsion spring.

And yes I'm waiting for my commission check as usual.....ya right.....I have no affiliation with any product. I just do the fixes for those who pay for my services. I offer advice freely to anyone who asks......without baiting for the outcome.

The original video clip is an excellent way to show this issue......plain and simple.
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post #8 of 76 Old 02-20-2013, 09:01 AM
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Quote:
Originally Posted by Tom Schmitz View Post
Your point is well taken, though, Damocles. I shall modify the title a bit...
Tom Schmitz, I appreciate the thread title revision, resulting in more accurate and precise prose!

And, I've no problem with anyone's lexicon whose nomenclature of "doohickey" includes idler shaft lever and spring only.

If the term, "doohickey," is an umbrella for the entire balancer chain tensioning system, other components may be involved besides the idler shaft lever and spring alone. For example, a dozen separate parts in this fiche comprise the balancer chain tensioning mechanism:

http://www.kawasakipartshouse.com/oe...96ac8/balancer

I consider the doohickey (idler shaft lever) and the tensioner spring as two separate parts. These components are identified and sold separately by Kawasaki, and marketed individually by Eagle Mike and other aftermarket vendors; that is, no "doohickey assembly" consisting of lever and spring exists, AFAIK. The doohickey-and-spring are not distributed as a "set," either may be replaced independently of the other.

Parts in the fiche: cap/bolt, idler lever/O ring, 7mm/lever, idler shaft (doohickey)/circlip-type-c 20mm/llever/washer, 20.3 x 36 x 1.5/spring/shaft-idler/sprocket-idler, idler/bearing-needle/spacer.

Generation 1 doohickeys (idler shaft levers) sometimes failed, disintegrated, broke, "grenaded." This malfunction sometimes resulted in catastrophic engine damage; cam chain de-sprocketing, bent valves, burst piston crowns, etc. Don't know of any Generation 2 OEM doohickeys with similar failure mode and consequent engine damage.

Spring issues surface, but as in the videoed example, without the trauma and carnage of the Generation 1 doohickey (idler shaft lever) failures.
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post #9 of 76 Old 02-20-2013, 09:12 AM
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Spring issues surface, but as in the videoed example, without the trauma and carnage of the Generation 1 doohickey (idler shaft lever) failures.


This is only true IF the owner takes the cover off and realizes the spring is broken or not doing it's job. IF they just continue to loosen the DOO adjuster without knowing this is at fault, it may allow the DOO to move in the more slack position resulting in the same carnage as if the old DOO had broken. Yes at a slower pace but the end product is the same.

IMHO....you are splitting hairs and doing the newer member or owners a disservice saying what you are saying. Sure technically you may be correct to a certain extent, but the concequences are the same.

You seem to live in a strange world of technical manuals and manufacturers recomendations. You offer advice as if you were the manufacturer.....which in some cases isn't the best way to help. Why not offer real world advice to help people rather than always muddying up the water to confuse a somewhat clearly outlined plan to solve this issue?

Your approach is a poor way to teach or help people who are looking for a simple solution to a simple problem. As usual.

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post #10 of 76 Old 02-20-2013, 09:19 AM
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What, an ad hominem (personal) attack on me, rather than addressing the Generation 2 doohickey maintenance history issue?

I'm shocked, SHOCKED!

willys, I cannot tell you how much I value your literary criticism, and character guidance!

As a highly-renown KLR Guru, your remarks mean a great deal to me, and--I'm sure, to many others!

Thanks for serving as an example to which others may aspire.

BTW, while we're discussing aftermarket parts, what do you think of the Thermo-Bob?

Last edited by Damocles; 02-20-2013 at 09:39 AM.
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