Another bad doohickey - 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 9 Old 03-02-2015, 02:09 PM Thread Starter
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Join Date: Feb 2014
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Another bad doohickey

Bike is a 2013 with 1,040 miles. Pulled it apart and the spring wasn't doing anything, it wasn't broken but was totally relaxed. Another confirmation case of what everyone already knew. Made a believer out of me.

Motor on!!

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light
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post #2 of 9 Old 03-02-2015, 03:34 PM
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Too bad about the SPRING TENSION problem; replace with torsion spring?
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post #3 of 9 Old 03-02-2015, 04:17 PM Thread Starter
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No, I bought the kit last summer from Eagle Mike that came with extension springs. The kit I bought isn't even offered anymore.

2013 KLR

16 Tooth sprocket, Doo done, DirtRacks Crash Bars, Bestem 929 top case, Kawasaki tall winscreen, Acerbis Supermoto front fender, LED dash lights and license plate light
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post #4 of 9 Old 03-03-2015, 07:54 PM
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Join Date: Oct 2013
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I found the kit with extension springs on Amazon, but I also ordered the torsion spring and bit. I hope to do more riding this year and don't want to worry about the doohickey.
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post #5 of 9 Old 03-03-2015, 08:33 PM
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Quote:
Originally Posted by lazeebum View Post
I found the kit with extension springs on Amazon, but I also ordered the torsion spring and bit. I hope to do more riding this year and don't want to worry about the doohickey.
2008 or later, fear not about the doohickey (no known verified cases of Generation 2 doohickey component failures). Spring tension? Could be an issue. The consequence of inadequate spring tension is excess balancer chain slack. Not particularly catastrophic, provided the spring doesn't break and fall into the innards, wreaking havoc.

Wishing you happy and carefree miles of additional riding.
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post #6 of 9 Old 03-10-2015, 06:01 PM
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Join Date: Oct 2013
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Did the doo. I used the torsion spring. The factory spring did not have any tension. It was not damaged or in danger of falling into the engine, but I feel better.
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post #7 of 9 Old 03-15-2015, 02:45 PM
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I'm new on here and I'm sort of befuddled by this cam chain tensioner issue on KLRs. With all these problems wouldn't you think a company like Kawasaki would have resolved this issue long ago? Why haven't they fixed the problem?
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post #8 of 9 Old 03-15-2015, 07:37 PM
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I'm new on here and I'm sort of befuddled by this cam chain tensioner issue on KLRs. With all these problems wouldn't you think a company like Kawasaki would have resolved this issue long ago? Why haven't they fixed the problem?
First, it ain't the cam chain tensioner, apexal! It's the balancer chain tensioner.

Kawasaki PARTIALLY fixed the problem with the 2008 models; more robust doohickey (idler shaft lever). Don't know of any component failures with this latter-day part.

Yet, spring tension issues surface. Loss of spring tension is rarely catastrophic, compared to doohickey grenading. Bad deal if spring breaks, falls into innards, but these instances are rare. Typical effect would be . . . spring fails to tension balancer chain when adjustment attempted; slack chain leads to excessive vibration. Yeah, yeah; vibration could conceivably shake the bike to pieces, but . . . would take a while.

Dat's da name o' dat tune. Don't know why Kawasaki hasn't fully dealt with the problem, except . . . I imagine a surprising number of KLRs are on the road, over a quarter-century plus of production, with absolutely stock and functional doohickeys.

Upgrading doohickeys remains sound maintenance, IMHO (especially on Generation 1s; torsion springs a good idea on all models).
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post #9 of 9 Old 03-17-2015, 11:02 PM
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Join Date: Jan 2012
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gone pulled my doo

I changed mine this past weekend. '09 with 1700mi on the clock.

There was no spring tension left. It wasn't going to fall off, but it easily slide off with two fingers.

Given how much stretch can occur in the balancing chain, you would think more tension would be available after only 1700 mi.

I only went to change it because... well... just because...

Everything I've read says thats what you do to a KLR... and the Thermo-bob
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