Eagle mike do hickey spring getting cut? - 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 17 Old 05-27-2019, 12:03 PM Thread Starter
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Eagle mike do hickey spring getting cut?

So this is the second spring ive put in and its 1/3 worn through at 4000km, is this normal? I know the stock springs tend to get cut.

On my klr650 thespring tends to wonder to the outside edge of the tensioner and make contact with the starter gear
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post #2 of 17 Old 05-27-2019, 12:51 PM
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It’s not fully installed. It needs to be popped up and over the top and into the groove.
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post #3 of 17 Old 05-27-2019, 01:12 PM
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What Tom said. Further; if you have the spring hole "clocked" wrong, it can make it harder to get it to sit into the groove. I'd replace the spring and drill a new hole, if necessary

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post #4 of 17 Old 05-27-2019, 02:33 PM Thread Starter
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What grove lol? There is only enough space for 1 coil behind the do hickey, the rest rides on top. I checked the indexing, its bang on the instructions that came with the kit.

How far is the dohickey suposed to run off the housing? Mine is nearly flush.

This klr has had literally every problem that has ever plagued the bike from the oil burning, deep hole, kack click, loud timing chain wurr, shock twist, unfixable oil plug leak. It wouldn't surprise me to find out it has other quarks.

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post #5 of 17 Old 05-27-2019, 02:45 PM Thread Starter
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Here is another angle, you can see one voil behind that takes up the entire "gap" the other two ride on the top
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post #6 of 17 Old 05-27-2019, 02:51 PM
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there should be a groove.......IIRC early EM doos (which were designed to run with the OEM style spring) didn't have the groove and neither did some chinese knock offs of Mike's doo.

Read: Installing a torsion spring

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post #7 of 17 Old 05-27-2019, 02:52 PM
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Groove pic.

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post #8 of 17 Old 05-27-2019, 03:12 PM Thread Starter
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Ok so my bike is once again proving to be a POS and I need to order a new dohickey or mod mine... since i need another new spring i might as well get a new dohicky.
Mind you the bike might be sold Wednesday, so i might not care anymore lol. Ive already spent a winter rebuilding the engine and gotten less then 200km out of it before another problem reared its head.
I think ive spent more time wrenching then riding in 2.5 years of ownership. 500km seems to be the max I can make without having to pull over for a couple minutes... or hours... to fix persistent issues, ive replaced half the engine at this point and it still gives me grief. Its not even high millage.
This bike is higher maintenance then my 30 year old army abused Iltis jeep.
I think i will be a proud owner of a dr650 by the end of june.... Sigh

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post #9 of 17 Old 05-27-2019, 03:44 PM
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If the 1/16th inch hole is drilled at at Upward angle it will tend to cause issues with proper torsion spring alignment into the groove in the top of an EM doo. If there is No Groove in the top of your replacement doo then it is not an EM Doo.

I have learned to drill the 1/16th inch hole at a slight Downward angle, which causes the Torsion spring to lean Towards the case instead of away from the case. And one can use a 3 corner file to deepen & lengthen the groove to help assist proper Retention of the Outer torsion spring coil.

If necessary drill another 1/16th inch hole at a LOOSER position & at a slight Downward angle. Looser is better than tighter & one may be able to judge the angle of the drill bit better with a long 6mm screw installed near the doo.

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post #10 of 17 Old 05-27-2019, 03:58 PM
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Quote:
Originally Posted by TechNeck View Post
I checked the indexing, its bang on the instructions that came with the kit.
Do you happen to have a picture of the drilled hole position?

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