doohicky/sub frame bolt issues - Kawasaki KLR 650 Forum
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Old 06-13-2013, 08:07 PM Thread Starter
Join Date: Feb 2010
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doohicky/sub frame bolt issues

do the newer klr 650s, 2012, 2013 have issues with the doohicky and sub frame bolt. I was told by a mechanic at a Kawasaki dealer that these are taken care of in the newer models.???????
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Old 06-13-2013, 08:20 PM
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Seriously? C'mon, dude. Do a quick search. It's been discussed "a few times."

And welcome to the forum.
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Old 06-14-2013, 09:56 AM
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Doohickey (idler shaft lever) was upgraded by Kawasaki and released with 2008 models. While I know of no latter-day doohickey component failures, other forum members may have evidence of GENERATION 2 (2008-2013 production) doohickey malfunctions to share (including, hopefully, images).

Regardless, I think it's fair to say, Generation 2 OEM doohickeys are more durable and reliable by far than Generation 1 OEM doohickeys. The choice, whether to install a stronger, tighter-fitting aftermarket doohickey with extended adjustment range, is yours.

Spring tension issues have surfaced among Generation 2 KLR650s and bear watching, IMHO.

Don't know about Generation 2 subframe bolt strength.
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Old 06-14-2013, 10:41 AM
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had a subframe bolt wiggle out on my 09, so it happens, nature of the offroad beast we drive.

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Old 06-14-2013, 01:08 PM
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Originally Posted by MISFIT View Post
I did a search and this thread popped up, but with no answer.
Come on, a quick search for "doohicky" using the "search" function above (between "new posts" and "quick links" showed 164 subjects.

Help us help you.
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Old 06-14-2013, 02:18 PM
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Hi Blockbuster!
I am sure if there had been any upgrades for the 2012 we would have heard. I believe the doo and spring still have the same issues that have been mentioned for the gen2 bikes. Sloppy fit on shaft and too short tension springs providing little to no adjustability have been reported. As to the subframe bolts which are known to be soft. You can upgrade with better bolts or do the drill through mod with a kit supplied by Eagle Mike. I also did a search on 2012 doohicky and only got 3 responses, none helpful.

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Old 06-14-2013, 05:03 PM
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Originally Posted by blockbuster View Post
do the newer klr 650s, 2012, 2013 have issues with the doohicky and sub frame bolt. I was told by a mechanic at a Kawasaki dealer that these are taken care of in the newer models.???????
Here's what Happy Trails says about Generation 2 subframe bolts, blockbuster:
Note: The kit includes four (4 bolts). On the E series bikes (2008+) only two bolts are used to upgrade the lower subframe. This is because the factory increased the diameter of the upper bolts from 8mm to 10mm on the E models.
So, your dealership mechanic spoke with some truth, blockbuster; Kawasaki upgraded the doohickey (idler shaft lever) and the upper subframe bolts with the Generation 2s (2008 and later models).

As mentioned; whether you wish to further refine your bike's configuration remains your choice alone.

Last edited by Damocles; 06-14-2013 at 06:08 PM.
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Old 06-16-2013, 07:00 AM
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Hi Blockbuster - I see posts by riders who pack a lot of cargo on their KLR who chose to increase the size of the fasteners at the frame connection point. Can't hurt to do it if you haul freight or a "husky" passenger, unless of course you goof up the drilling your frame part...

At around 7500 km I took apart my engine to install an Eagle Mike balancer lever (aka doohickey) kit and radial style spring. The OEM lever is stamped steel. It doesn't look as flimsy as the pre 2008 model's lever. The tension spring was completely slack i.e. the system was no longer able to adjust itself like it is supposed to during maintenance. You cannot see the adjustment not happening from outside the engine doing the maintenance procedure for tensioning the chain.

When the tension is gone from the OEM spring no adjustment happens. But you don't know because you cannot see it...
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Old 06-28-2013, 03:26 AM
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Join Date: Jun 2013
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'09 with 12k. Doo spring had no tension and lever was very sloppy on the shaft. Upgraded to EM lever with torsion spring and she purrrrs. Lower subframe bolts were loose so 18ft-lbs and some red loctite. Upper bolts were changed when I installed my Motech bars. I used blue loctite on them due to the larger diameter.
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Old 06-28-2013, 08:33 AM
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Goes to show you don't always believe what dealers have told you or the mothership.....go by what the majority of owners have seen and reported from their experiences. Those who work on these bikes usually know what happens over someone who just says what the manual or dealers says as the truth.

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