Kawasaki KLR 650 Forum - Reply to Topic
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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  Topic Review (Newest First)
05-19-2008 07:57 AM
DXKLR The stock lever or spring is prone to breakage. Yes the 08's are better, but there have been some documented cases of the lever already breaking on those, and the spring is still the same spring used in the earlier models, which again, is prone to breaking. The reason for the spring breaking is at the factory, the end that is wound to make an attachment point has a sharp bend, causing a stress point on the spring. The Eagle Mike aftermarket spring does not have this sharp bend, but a uniform curve. The doohickey from the earlier models is made from two pieces that are tack welded together. Their quality is sub par. Alot of times the doohickey won't work is because of when the owner of the bike adjusts the doohickey at each oil change, they are not using a torque wrench and over tightening the adjustment bolt. This excess pressure pushes the collar of the bolt up against the face of the lever, causing a dimple or impression and also creating a curvature to the face of the lever, therefore reducing its ability to slide back and forth to create tension on the chain. The adjustment bolt should not be tightened more than around 60 INCH pounds for an OEM and 72 INCH pounds for the Eagle Mike's lever. The reason for engine failure from a failed doohickey is that the internal chain becomes loose and if revving or bouncing around hard from riding, the chain can jump time allowing the valves to come into contact with the piston and therefore causing major damage to the engine. Hope this helps some.. Just do a google on KLR650 Doohickey and you will get a few days worth of reading. If your's has not been changed, it is worth doing it, to have peace of mind knowing that won't ever be a problem furthe on down the road.
05-19-2008 07:42 AM
Irish07 what kind of problems does this create on an older bike that has the stock lever and springs?
05-19-2008 05:35 AM
Florida Marine
Quote:
Originally Posted by mscallahan07 View Post
thanks major! can you explain it any more simply?
The doohicky is a balancer lever that is secured with a spring that keeps tension on the balancer chain. The lever is a POS that cracks/falls apart and does not maintain adequate tension on the balancer chain - which can lead to engine failure.

2008 models are fixed - in fact the kit I bought from MSM has a stock 2008 part.

Sean
05-19-2008 01:06 AM
Irish07 thanks major! can you explain it any more simply?
05-18-2008 05:34 AM
Florida Marine
Quote:
Originally Posted by mscallahan07 View Post
what is a doohickey? i have been interested in klr's for a few months now and i am brand new to this forum (literally a few minutes!) i am a klr owner in the making and i hope to gain alot of knowledge from you guys! thanks for putting up with my silly questions.
mike
http://www.multisurfacemotorcycling..../fft011503.htm

Read this (and much more on their great site) for more info...

Sean
Sunday duty at the II MEF HQ today...no riding for me.
05-18-2008 12:30 AM
Irish07
stupid question

what is a doohickey? i have been interested in klr's for a few months now and i am brand new to this forum (literally a few minutes!) i am a klr owner in the making and i hope to gain alot of knowledge from you guys! thanks for putting up with my silly questions.
mike

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