doohicky problems - Kawasaki KLR 650 Forum
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post #1 of 13 Old 11-03-2008, 10:39 PM Thread Starter
 
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doohicky problems

I would like to know if all years of klr650 have yhe doohickey problems and at what milage should the change out take place
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post #2 of 13 Old 11-04-2008, 04:57 AM
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Yes all years have the problem. I have seen bikes with less than 1000 miles have broken springs or doo's, and I have seen bikes with 20,000+ where there was no problem.
Kawasaki changed the doo on the 08's but still use the same cheap spring, and the new Kawasaki doo doesn't compare with the doo Eagle Mike makes. $40 isn't too much to pay for the peace of mind you get with the upgraded doo.
About 1/3 of the bikes that I have seen apart have had either a broken spring or broken doo.

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post #3 of 13 Old 11-04-2008, 10:49 AM
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It is pretty much advised to just go ahead and change out the doo no matter the mileage or year, if nothing else for peace of mind. It is not a difficult thing to do if you have any mechanical ability at all.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #4 of 13 Old 11-04-2008, 03:07 PM
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Yep.. We did one this weekend, plus a complete subframe bolt upgrade in 3 hours, and we weren't in any hurry..

2007 bike, and the factory doo and spring were fine, but had never been adjusted, either.. We did MajorLagg's bike and it had a bad spring..

Doo the doohickey and relax with peace of mind.. I can think of worse places to spend $40..
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post #5 of 13 Old 11-07-2008, 05:43 PM
 
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doo doo

What and where do I get the replacement chain bit? Can we use gasket sealer instead of a new gasket on the casing?
Has anyone asked Kawasaki about a recall??
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post #6 of 13 Old 11-08-2008, 06:20 AM
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TPI carries everything you will need:
http://www.tpimotorcycleparts.com/
Click on the Clutch/Engine link to get to the page with the parts.
I do not recommend using sealer instead of a gasket. If you are careful removing the side casing, 9 times out of 10 the original will be fine.
You will also need the flywheel puller. That is the big black looking bolt. They are extremely difficult to find at a hardware store, due to the thread pitch. It's easier to just go ahead
and purchase it when you get your doo. As for the special wrench to hold the flywheel, a cheap 1 1/4 wrench from an auto parts store worked just fine.
Two people make the job MUCH easier.

This link will give you step by step instructions. It is not a very difficult thing to do, just take your time and go slowly and double check everything.
http://www.klr650.marknet.us/Doohickey.pdf

Hahaha, as for a recall, this has been discussed for "many" years. Big Kaw is not going to admit there is a problem, never have. Altho on the new 08's they did redesign the doo a bit, but it still is not top notch and the spring is still a bad design that lends itself to breaking. Eagle Mike's replacement is the best there is and is time proven. Once it is in you never worry about it again.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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Last edited by DXKLR; 11-08-2008 at 06:22 AM.
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post #7 of 13 Old 11-16-2008, 01:00 AM
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For the '08s and '09s the issue isn't the doohickey its the spring and it ain't a big deal anymore on the new models. I have 22,000+ miles on my '08 with the stock doohickey and spring. Checked at 18,000 miles and all was ok. The spring still had tension. This winter mine will get the Eagle Mike doohickey treatment because it is better but the new Kawa doohickey set-up is good for 22,000+ miles easy. Don't sweat it. Militant doohickitistas seem to disagree.
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post #8 of 13 Old 11-16-2008, 10:30 AM
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Quote:
Originally Posted by ScareCrow View Post
For the '08s and '09s the issue isn't the doohickey its the spring and it ain't a big deal anymore on the new models. I have 22,000+ miles on my '08 with the stock doohickey and spring. Checked at 18,000 miles and all was ok. The spring still had tension. This winter mine will get the Eagle Mike doohickey treatment because it is better but the new Kawa doohickey set-up is good for 22,000+ miles easy. Don't sweat it. Militant doohickitistas seem to disagree.
Kawa must have run out of the extra long springs when they built your bike.
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post #9 of 13 Old 11-16-2008, 12:29 PM
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See what I mean.
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post #10 of 13 Old 11-16-2008, 04:46 PM
 
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Do we have any idea as to the percentage of KLRs that suffer this problem?
Gosh I love this machine

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