Kawasaki KLR 650 Forum - Reply to Topic
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

Thread: doohicky/sub frame bolt issues Reply to Thread
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  Topic Review (Newest First)
06-28-2013 09:27 PM
Originally Posted by willys View Post
If you carry any type of load or are of the larger size of human, think about the drill through subframe kit from EM. It comes with everything you need.
I saw on another forum a frame bolt had broken while the rider was on a trail ride,I was pleased to have willy replace mine with a drill through kit.
06-28-2013 09:42 AM
willys If you carry any type of load or are of the larger size of human, think about the drill through subframe kit from EM. It comes with everything you need.
06-28-2013 09:39 AM
Sandstone To clarify, I used the Motech supplied 10.9 upper bolts and the factory lower bolts. I'll get some stronger lower bolts next time I place an order.
06-28-2013 09:33 AM
willys Goes to show you don't always believe what dealers have told you or the mothership.....go by what the majority of owners have seen and reported from their experiences. Those who work on these bikes usually know what happens over someone who just says what the manual or dealers says as the truth.

06-28-2013 04:26 AM
Sandstone '09 with 12k. Doo spring had no tension and lever was very sloppy on the shaft. Upgraded to EM lever with torsion spring and she purrrrs. Lower subframe bolts were loose so 18ft-lbs and some red loctite. Upper bolts were changed when I installed my Motech bars. I used blue loctite on them due to the larger diameter.
06-16-2013 08:00 AM
Slowpoke Hi Blockbuster - I see posts by riders who pack a lot of cargo on their KLR who chose to increase the size of the fasteners at the frame connection point. Can't hurt to do it if you haul freight or a "husky" passenger, unless of course you goof up the drilling your frame part...

At around 7500 km I took apart my engine to install an Eagle Mike balancer lever (aka doohickey) kit and radial style spring. The OEM lever is stamped steel. It doesn't look as flimsy as the pre 2008 model's lever. The tension spring was completely slack i.e. the system was no longer able to adjust itself like it is supposed to during maintenance. You cannot see the adjustment not happening from outside the engine doing the maintenance procedure for tensioning the chain.

When the tension is gone from the OEM spring no adjustment happens. But you don't know because you cannot see it...
06-14-2013 06:03 PM
Originally Posted by blockbuster View Post
do the newer klr 650s, 2012, 2013 have issues with the doohicky and sub frame bolt. I was told by a mechanic at a Kawasaki dealer that these are taken care of in the newer models.???????
Here's what Happy Trails says about Generation 2 subframe bolts, blockbuster:
Note: The kit includes four (4 bolts). On the E series bikes (2008+) only two bolts are used to upgrade the lower subframe. This is because the factory increased the diameter of the upper bolts from 8mm to 10mm on the E models.
So, your dealership mechanic spoke with some truth, blockbuster; Kawasaki upgraded the doohickey (idler shaft lever) and the upper subframe bolts with the Generation 2s (2008 and later models).

As mentioned; whether you wish to further refine your bike's configuration remains your choice alone.
06-14-2013 03:18 PM
justjeff Hi Blockbuster!
I am sure if there had been any upgrades for the 2012 we would have heard. I believe the doo and spring still have the same issues that have been mentioned for the gen2 bikes. Sloppy fit on shaft and too short tension springs providing little to no adjustability have been reported. As to the subframe bolts which are known to be soft. You can upgrade with better bolts or do the drill through mod with a kit supplied by Eagle Mike. I also did a search on 2012 doohicky and only got 3 responses, none helpful.
06-14-2013 02:08 PM
Dan Diego
Originally Posted by MISFIT View Post
I did a search and this thread popped up, but with no answer.
Come on, a quick search for "doohicky" using the "search" function above (between "new posts" and "quick links" showed 164 subjects.

Help us help you.
06-14-2013 11:41 AM
Scrapper had a subframe bolt wiggle out on my 09, so it happens, nature of the offroad beast we drive.
This thread has more than 10 replies. Click here to review the whole thread.

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