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.

Thread: best doo-hickey replacement ? Reply to Thread
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  Topic Review (Newest First)
05-14-2011 10:00 AM
vatrader Thanks for the excellent images of the items you replaced. Every picture tells a story, and yours is one that bears repeating.

You just covered a big step towards turning your bike from "reliable", to "extremely reliable".
05-14-2011 09:48 AM
outdoorgb Well I finished up the doohickey replacement and now have an Eagle Mikes installed... Cleaning gasket material was my only issue, took a while.

Condition of OEM:

Spring was connected and intack...easily removed...was it really keeping the shaft tight? Hard to say.

The doo itself looked like it had not been adusted much but can't say for sure. Bike only has 4500 and is just new to me.

I can see where the washer on the adjustement bolt made contact on the face...AND on the opposite side (bottom pic) I can see wear marks near the thinest part of the slots (not real shinny in pic but are)...this would help identify a possible cause for breakage.

Photos:

Spring


Doohickey


05-09-2011 03:34 PM
outdoorgb
Quote:
Originally Posted by Damocles View Post
You don't need no stinkin' oil for these replacement parts IMHO, outdoorgb; however, if you insist, or if your conscience bothers you . . . use regular motor oil.
I appreciate the quick reply... I'll reassemble the components in the same condition they came out. is blue loctite recommended for the case bolts? is blue loctite recommended for the case bolts when I reassemble?
05-09-2011 03:07 PM
Damocles
Quote:
Originally Posted by outdoorgb View Post
Several sites list to "coat" or "oil" all components upon reassembly. What do you guys use? I appreciate the info.
You don't need no stinkin' oil for these replacement parts IMHO, outdoorgb; however, if you insist, or if your conscience bothers you . . . use regular motor oil.
05-09-2011 02:19 PM
outdoorgb New guy on the board...couple of questions.

First, just got my 06 KLR on Saturday...4500 miles. I'll post pics when I can.

I ordered the Eagle Mike kit this morning...what a great guy to talk with.
I have oil, filter, kit on the way, and a good shop.

What else to I need? Several sites list to "coat" or "oil" all components upon reassembly. What do you guys use? I appreciate the info.
08-04-2010 05:35 PM
Rockyrider Seems to be good advice from those guys and there's some good background info as well.

They recommend waiting until the warranty expires on a 08 or later bike which might not be a bad idea. The inspection port idea is interesting but probably wouldn't work if you switch to the torsion spring?

I'm happy I did the full doo-hickey even though I'm still inside the warranty period and low kms.
08-04-2010 05:16 PM
vatrader
Quote:
Originally Posted by ironpole View Post
How about an 08+ ?
Whats the scoop on the doo-hick?
I am not aware of any confirmed balancer lever failures on the Gen II [08 & up] KLR 650's. The springs seem prone to lose tension, and conventional wisdom implies they should be swapped out with after market springs. The torsion type spring currently is the most popular. These springs are available from a number of sources. Here is an interesting article about the later model bike's and the upgraded balancer system.


http://www.topgunmotorcycles.com/200...klr_page3.html

I am considering the installation of one of their inspection ports, to better monitor what is going on down there in the balancer region.

Balancer Spring Inspection Port Kit
Applications: Kawasaki KLR650 '87 - 2010

http://www.topgunmotorcycles.com/Pro...s/klrprod.html

This is an interesting outfit. They offer some tech articles I find informative. They also offer shock service and spring replacement for those looking to improve their suspension. Very helpful on the phone, knowledgeable, willing to help you make the right choices. I think their main focus is setting up rally type bikes, and long distance multi-surface long distance traveler's bikes.

http://www.topgunmotorcycles.com/articles.html
08-04-2010 05:13 PM
Rockyrider
Quote:
Originally Posted by ironpole View Post
How about an 08+ ?
Whats the scoop on the doo-hick?
Opinions will vary but I'd say it's worth it, if only for peace of mind.

The 08 and later idler shaft lever (doohickey) is quite good quality but not as good as the Eagle Mike version and upgrading to the torsion spring is worth doing anyways.
08-04-2010 05:02 PM
Lockjaw
Quote:
Originally Posted by ironpole View Post
How about an 08+ ?
Whats the scoop on the doo-hick?
The 08 has a beefed up Doo, but my spring had no tension when I changed it at 3K? Close to that. You want to check it out, and if you got the scrilla put an EM doo in there.



08-04-2010 04:53 PM
Rockyrider
Quote:
Originally Posted by Lockjaw View Post
Was there slack in the spring? And good on ya, dude.
No, it all looked good including the spring.

But you don't know that until you take it apart and you might as well do the upgrade as you've pretty well done all the work by then.
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