Remove crash bars to replace doohickey - Kawasaki KLR 650 Forum
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post #1 of 4 Old 03-23-2017, 07:33 PM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Toronto
Posts: 61
Remove crash bars to replace doohickey

Is it necessary to remove the left side crash bar to do the doohickey?

If so I'll wait to install them.
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post #2 of 4 Old 03-24-2017, 05:32 PM
1st Gear
Join Date: Mar 2017
Location: Toronto
Posts: 15
I think it may depend on the crash bars, but I'd think you should be OK. What bars are you running? I just put SW Motech's on my 2013 and while I haven't looked at it closely, I'm hoping I don't need to remove the crash bar to do my doo.

BTW - you're in Toronto? Do you have the doohickie tools? I just bought a set from someone if you need to borrow them.
Tim is offline  
post #3 of 4 Old 03-25-2017, 01:24 AM
2nd Gear
Join Date: Mar 2017
Posts: 389
Just did the Doo on my '07. I installed a set of SW-Motech Crash Bars after I replaced the Doo. You will have to remove these Crash Bars. Removing the Alternator Cover, not to mention the Flywheel will require more clearance than these Crash Bars provide. Even so, the few minutes it takes to R&R a Crash Bar will be more than rewarded by not having to work around it. This also probably applies to any aftermarket Skid Plate IMHO. As with most things YMMV of course!
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post #4 of 4 Old 03-25-2017, 10:17 PM
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Join Date: May 2014
Location: Texas
Posts: 1,260
I have SW Motech bars on my 2008 and a skid plate who's brand I don't remember. While on a road trip I was able to remove the left outside cover with the stator in it to check the doohickey tension. I had to use an angel grinder to cut bit of the skid plate to make room.

I did not want to remove the bars because of my experience trying to reinstall those bars after having dropped the bike fairly hard a few times. The bars did their job of protecting the bike, but were stressed/tweaked a bit and getting all the bolts to fit back in required a lot of force from ratchet straps and crow bars.

Now, when I occasionally notice that the bars are a little closer to the plastic than usual, I park the bike between two pickups and attach some heavy ratchet straps or come-along cable pullers to the bars and crank them back out a bit.
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