another Doohickey Questions / Problem - Page 2 - 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 #11 of 25 Old 01-26-2020, 02:35 PM
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Did you have doohickey in or were installing now.
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post #12 of 25 Old 01-26-2020, 02:36 PM Thread Starter
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i'm doing it now
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post #13 of 25 Old 01-26-2020, 02:38 PM
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Gwn do you put doohickey on all yours?
Yes. And the torsion spring upgrade. The E-M doohickey kits have sure gotten expensive!
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post #14 of 25 Old 01-26-2020, 02:38 PM
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Thanks Moosehead. Im just tearing mine apart for bigger bore. Guess it be a good idea to check that. Approximately 9500km on 2010.
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post #15 of 25 Old 01-26-2020, 02:40 PM
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Thanks GWN. Alternative likely more. Lol.
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post #16 of 25 Old 01-26-2020, 03:00 PM
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...
I also photograph the balancer location
the metal looks sandblasted

>image removed, see above<[/IMG]
To my eye, that looks like the engine was run with a loose adjusting bolt for a while. That would cause the chain to go to pretty much a full-slack condition. At every spot where the chain has to change direction as it goes around a sprocket it will hit the case if there is a case to hit.

You might want to dress that area down so that the lever can't hang up in the grooves and on the sharp spots.
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Last edited by Tom Schmitz; 01-26-2020 at 03:03 PM.
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post #17 of 25 Old 01-26-2020, 03:10 PM
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...The rubber cush, that the chain rests on, becomes compressed over time, and develops conforming flat spots, which allows the chain to ride deeper in between the sprocket teeth...
Fortunately, his look pretty good. See post #3.

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“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #18 of 25 Old 01-26-2020, 03:11 PM
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As someone who accidentally ran an engine with the counterbalancer chain full slack, I can attest that you can make it approximately 30 kms before the chain snaps, and the engine grunches to a halt, making expensive noises.

Teardown revealed the end broken off a doohickey torsion spring. I'd done an oil change and doohickey adjustment day before, in prep for a trip. ...ran it after the oil change, thought it sounded a bit different, but ignored that (silly me).

One theory, is that it's possible to nick the spring, if you're using sharp edged needle nose pliers (for example)... or that the edge where the doohickey contacts the spring can wear into the spring - I slightly radius that contact point now when I install a doohickey.
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post #19 of 25 Old 01-26-2020, 03:15 PM
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Fortunately, his look pretty good. See post #3.
I saw that. Your suggestion that the adjuster bolt was loose makes sense. It wouldn't be the first KLR with the counterbalancer chain ran slack :^(
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post #20 of 25 Old 01-26-2020, 03:25 PM
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I credit @pdwestman and his keen eye for seeing this sort of thing and knowing what it was. The first time I saw it I thought it was fretting and Paul set me straight that he'd seen late-model KLRs running with loose adjusting bolts.

Tom [email protected]

“I decided I could lose nothing by the soft approach. If that didn't produce for me—and I didn't think it would—nature could take its course and we could bust up the furniture.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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