another Doohickey Questions / Problem - Kawasaki KLR 650 Forum
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post #1 of 25 Old 01-26-2020, 10:29 AM Thread Starter
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Join Date: Jul 2018
Location: Quebec
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another Doohickey Questions / Problem

Hi Everyone

this weekend, i'm doing my Doohickey on my 2013 klr.

and i have a problem, something i have never seen on any videos or pictures of "how to" Doohickey

it seems the tension chain is rubbing the low end of the case, and groove the metal.
see pictures below

I bought this used bike 2 years ago,
I thought the Doohickey maybe had already been changed, because there is an orange gasket silicone all around the cover, but it's a "OEM" Doohickey and spring inside.
may be changed by the dealer ?

its seems something is not not well installed, but i don't know what.
i have remove the tensioner sprocket, and everything looks OK according to my Clymer book.
but i am not a specialist... it is my first Doohickey change

has anyone seen anything like that ?










how to make it stop rubbing ?

Thanks
and sorry for my bad English, i hope it is understandable.
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post #2 of 25 Old 01-26-2020, 10:58 AM
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It looks like your balancer chain has been run very loose. I would expect that you have similar damage at the upper rear balancer as well.


It would be interesting to see what the inner cover looks like at the spot that the balancer adjustment lever rides on. That may show evidence that the engine was run with the adjusting bolt being loose.

Proper installation of the aftermarket lever and spring should cure this.
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post #3 of 25 Old 01-26-2020, 12:12 PM Thread Starter
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hello,

Thanks, it worries me less.

you're right, the upper rear balancer is completely grinded.
I hadn't see the top..



I also photograph the balancer location
the metal looks sandblasted

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post #4 of 25 Old 01-26-2020, 12:16 PM Thread Starter
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I will continue my Eagle Mike Doohickey installation.
Thanks.
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post #5 of 25 Old 01-26-2020, 12:41 PM
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There appears to be a crack in the housing near where the shaft for the adjuster sprocket fits, at about the 11 o'clock position . Not sure how far the crack extends.
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post #6 of 25 Old 01-26-2020, 12:50 PM
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Is the doohickey a must change as its only a matter of time before failure? Even on new series?
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post #7 of 25 Old 01-26-2020, 12:51 PM
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How many miles/km on your bike Moosehead?
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post #8 of 25 Old 01-26-2020, 12:58 PM
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Unfortunately, the fix for the chain rubbing on the case is to replace the counterbalancer sprockets. 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. My understanding, is that the counterbalancer chain stretches a bit too, also contributing to what you're seeing there. I may have some counterbalancer sprockets kicking around for show & tell that illustrate this.

Edit... here you go. This is a set of counterbalancer sprockets out of a '92. You can see the rubber cush are beat up bad, very compressed:



And in comparison, this pic is from an '01 spare engine I'm building up, and the idler sprocket cush has very little compression dimpling:



I suspect that running the chain slack is what accelerates wear on the rubber sprocket cushions.
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Last edited by GreatWhiteNorth; 01-26-2020 at 01:31 PM.
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post #9 of 25 Old 01-26-2020, 01:30 PM
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Gwn do you put doohickey on all yours?
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post #10 of 25 Old 01-26-2020, 01:33 PM Thread Starter
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the bike has 35 000 km, approx 21 000 miles

i have noticed the "crack" on the housing too. fortunately, it's only a scratch on the paint

thanks for the counterbalancing issue/solution.
i think i will live with it for now
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