Doohicky change,wheres the video online?? - Kawasaki KLR 650 Forum
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post #1 of 12 Old 07-05-2010, 11:40 AM Thread Starter
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Doohicky change,wheres the video online??

I'm getting ready to change the dreaded DOOHIKY ,,and I've heard that there is step by step instructions on how to do this,,,,but where???? Can't find a link to review the proccess ,,,any info???
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post #2 of 12 Old 07-05-2010, 11:46 AM
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post #3 of 12 Old 07-05-2010, 12:29 PM Thread Starter
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Thanks again,,it looks doable,,,,just have to order the parts, and wait for the 100 degree temps to moderate a bit,,,so,,,,,,,,,,until then.Thanks.
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post #4 of 12 Old 07-05-2010, 02:36 PM
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Here's a link and I would bookmark this site - the everything you wanted to know and do to a KLR and then some site.

http://www.klr650.marknet.us/doohickey.html

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #5 of 12 Old 07-05-2010, 08:39 PM Thread Starter
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Originally Posted by klr4evr View Post
Here's a link and I would bookmark this site - the everything you wanted to know and do to a KLR and then some site.

http://www.klr650.marknet.us/doohickey.html
WOW,,,,,That is a great link,,,thank you much,,,,,,,I'll study the steps over the next week or so,,and give it a whirrl. I did watch the U-tube video about the doo change,,,,and they said something about a thrust washer behind the starter gear,,is that true? I didn't see anything about it on the above stated link,,when I take it apart,,,I'll look for it just in case. What great info,,I now feel as though I can really do this myself now,,when before on sites,,,I heard discriptions and accounts of how to do it and I was not sure I wanted to try it. But now I DO want to try it,,,what about the "razor blade" that awaits down in there,,I've heard about that also, is that a concern ? Thanks again.
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post #6 of 12 Old 07-05-2010, 10:08 PM
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The washer behind the starter gear usually don't come off with the gear when you remove it. If it does not an issue as long as you remember to put it back. When I did mine I laid the gear on a piece of plastic. Put it all back together only to find the washer had stuck to the plastic and I didn't notice. Take it all apart again.

The washer you want to be very mindful of is the one behind the doohickey shaft. You can't see it. When you are removing the spring off of the doohickey hold your finger on the shaft so it doesn't move out and the washer drop off and into the crankcase. Same goes for when you remove the doohickey itself. Hold the shaft in place.


As to the "razor bade" I do not know to what you are referring.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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Last edited by klr4evr; 07-05-2010 at 10:14 PM.
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post #7 of 12 Old 07-05-2010, 10:33 PM
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"Razor Blade"

Hey Scooter!

I think the razor blade you are referring to was mentioned on 650.net. A fellow posted this:

I recently "did the doo" on my '09 and had a rather unpleasant experience after re-installing the alternator rotor. While wiping out the interior of the rotor (with a paper towel) to remove the usual bits of filth inherent in any motor work, I found that a circumferential razor blade had been cleverly machined into the rotor, maybe 1/4 inch out from the inside edge.

Imagine my surprise as it sliced neatly into my middle finger as I bore down a bit and smartly wiped out the inside of that rotor. After saying some really bad words and wrapping my finger with a paper towel to stop that annoying dripping of blood, I examined the inside of the rotor but couldn't see any obvious raised surface. So at least I didn't have to feel stupid for missing something obvious.

Just a word to the wise when wiping out that rotor . . .

I think he was referring to a sharply machined edge that he cut himself on... Same thing with casting flash, it can bite you! Good luck with the Doo

Cheers,
Stew
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post #8 of 12 Old 07-05-2010, 10:46 PM
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Ya, that rotor is sharp. I've done that too. Mixed some blood in with the oil.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #9 of 12 Old 07-06-2010, 02:23 PM Thread Starter
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Quote:
Originally Posted by 650Stew View Post
Hey Scooter!

I think the razor blade you are referring to was mentioned on 650.net. A fellow posted this:

I recently "did the doo" on my '09 and had a rather unpleasant experience after re-installing the alternator rotor. While wiping out the interior of the rotor (with a paper towel) to remove the usual bits of filth inherent in any motor work, I found that a circumferential razor blade had been cleverly machined into the rotor, maybe 1/4 inch out from the inside edge.

Imagine my surprise as it sliced neatly into my middle finger as I bore down a bit and smartly wiped out the inside of that rotor. After saying some really bad words and wrapping my finger with a paper towel to stop that annoying dripping of blood, I examined the inside of the rotor but couldn't see any obvious raised surface. So at least I didn't have to feel stupid for missing something obvious.

Just a word to the wise when wiping out that rotor . . .

I think he was referring to a sharply machined edge that he cut himself on... Same thing with casting flash, it can bite you! Good luck with the Doo

Cheers,
Stew
Well hello there,,havent heard from you in a while,,yea,,,,thats the culprit I was referring to,,,,,,in fact I may have read that post a while back,,,and somthing about it was in the back of my mind,,over the past week or so as I prepare to change the " HIKY",,I wonder if I could DREMMEL that edge a bit,,would like to keep my fingers after the work is done.Maybe the magnet would "collect" the shavings from that and really cause problems,so where does one "grip" the rotor to keep from getting cut????

Last edited by Scooter; 07-06-2010 at 02:29 PM.
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post #10 of 12 Old 07-06-2010, 02:34 PM Thread Starter
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Quote:
Originally Posted by klr4evr View Post
The washer behind the starter gear usually don't come off with the gear when you remove it. If it does not an issue as long as you remember to put it back. When I did mine I laid the gear on a piece of plastic. Put it all back together only to find the washer had stuck to the plastic and I didn't notice. Take it all apart again.

The washer you want to be very mindful of is the one behind the doohickey shaft. You can't see it. When you are removing the spring off of the doohickey hold your finger on the shaft so it doesn't move out and the washer drop off and into the crankcase. Same goes for when you remove the doohickey itself. Hold the shaft in place.


As to the "razor bade" I do not know to what you are referring.
Good to know,,,thanks,,,,I hate when I put stuff together and some "thing" doesnt go back till after the fact,,,,,oh well,,,live and learn I guess,,,thanks for the info,,,
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