Balance Chain Adjustment - 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 13 Old 09-12-2014, 06:44 PM Thread Starter
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Balance Chain Adjustment

How do you tell when the factory Gen II doohickey isn't working anymore?
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post #2 of 13 Old 09-12-2014, 08:30 PM
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My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 13 Old 09-12-2014, 08:48 PM
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First indication

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Originally Posted by klr4evr View Post
There must be an easier way?



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post #4 of 13 Old 09-12-2014, 09:08 PM Thread Starter
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Wow! Maybe you should have checked your doohickey more often!
All kidding aside, I have an EM kit on order, just wondering if you can tell when the factory piece isn't doing its job.
My 2009 has 7000 miles on it, and I adjust it every oil change.

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post #5 of 13 Old 09-12-2014, 10:41 PM
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Normally, when you adjust the balancer the engine becomes noticeably quieter. If you pay attention to how the engine sounds and if, after adjustment, it doesn't sound a bit better then it is likely that the spring has used up all it's tension.

Reports on the Gen 2 is that the spring is found to be slack as early as the first adjustment and as late as 'never', but several thousand miles seems to be the norm.

If in doubt, remove the outer cover; you'll be able to see the bottom of the lever. Using a long probe of some sort, reach in and try to move the lever. If it moves, she's done.

I'll find a picture in a minute.

The visible part of the doohickey is outlined in red here:
r

You can reach in and catch the end of the arc on both sides and see if it wiggles.

Tom

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post #6 of 13 Old 09-13-2014, 01:29 AM
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My post was a joke of course. About the only way you can tell if a Doohickey is still doing it's job is to open it up and check.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #7 of 13 Old 09-13-2014, 10:27 AM
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If the machine is not vibrating excessively when the engine is running, chances are balancer chain tension is adequate. No indication of whether sufficient spring tension exists for future adjustments is discernible, however, without some disassembly.

Obviously, the hold-down bolt must be loosened to manipulate the doohickey, after the case cover is removed. Don't forget to torque it down after the inspection!
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post #8 of 13 Old 09-13-2014, 10:32 AM Thread Starter
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I ordered a doohickey kit with tools from Eagle Mike Thursday. I've never been that far into a four stroke before. It will be interesting.
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post #9 of 13 Old 09-13-2014, 12:37 PM
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Just follow his instructions closely and you will have no problem, you will be surprised how easy it is...

Don't overtorque bolts during reassembly! It is a common issue for people without a proper torque wrench working with aluminum casings.
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post #10 of 13 Old 09-13-2014, 12:46 PM Thread Starter
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I recently bought a set of torque wrenches with 1/2",3/8" foot pounds, and 1/4" inch pounds. I also have an old Craftsman beam type 1/2". I've watched a video, and it doesn't look all that bad, but I'd rather have someone there that's done it before.
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