[CentralOregonKLR]

Hi there, I just bought a 2001 KLR650 from the original owner who took great care of it, but was adamant that the Doohickey thing was no a concern so he never changed it. Not knowing much about it I used the internet and by the power of statistics decided for the $200 kit it was worth doing the Eagle Mike upgrade.

Spring was fine and intact, doohickey was actually broken (Pictures below). It looks like it has been broken a while. I say this because when I opened the case what I though was debris mixed with grease fell out bet it was metallic (stuck to magnet) so ground up metal likely.

So the bike ran and drove fine before i pulled it apart. I cleaned out left side case thoroughly, but where is the rest of this metal? Im not really feeling cracking the case since the bike seems fine. I was thinking flex magnet in the pan to look for it and then a magnetic drain plug with frequent oil changes?

Any advice would be great, I am all ears and look forward to hear from the more seasoned KLR crew

 

[garrettL]

It will either be in the bottom of the case or trapped in the oil screen inside the right cover

 

[CentralOregonKLR]

It will either be in the bottom of the case or trapped in the oil screen inside the right cover

Thank you. So bottom of the case on the right side? I thoroughly cleaned and check the left side.

 

[tomo]

Welcome. Central Oregon is riding heaven, when the snow is gone. Hang that thing on your key chain. Probably rolling around in the bottom of your engine. I'm not sure if a piece that big can make it up to your oil screen or not. Cleaning your oil screen is worth doing anyway. Buy a magnetic low profile oil drain bolt, a Clymers manual, appropriate engine oil and filter, radiator fluid and necessary gaskets to open and close your engine right side case. Easy to do. EM has all that stuff. Seat recovering is way easy also. Use the "search community" bar up top.

 

[tomo]

Obviously, you don't need to have your motor torn down as in the video.

 

[CentralOregonKLR]

Welcome. Central Oregon is riding heaven, when the snow is gone. Hang that thing on your key chain. Probably rolling around in the bottom of your engine. I'm not sure if a piece that big can make it up to your oil screen or not. Cleaning your oil screen is worth doing anyway. Buy a magnetic low profile oil drain bolt, a Clymers manual, appropriate engine oil and filter, radiator fluid and necessary gaskets to open and close your engine right side case. Easy to do. EM has all that stuff. Seat recovering is way easy also. Use the "search community" bar up top.

Thank you! You noticed my custom seat job... I needed something to get me by so I could ride the second the sun peaked out! I will get working on that, and start pulling the right side cover off.

 

[CentralOregonKLR]

Obviously, you don't need to have your motor torn down as in the video.

To clarify. this part could not be in the oil pan, because it would have to pass through the oil strainer to get thier correct? Having never taken one of these apart I am not clear on the oil pathways.

 

[DPelletier]

Hi there, I just bought a 2001 KLR650 from the original owner who took great care of it, but was adamant that the Doohickey thing was no a concern so he never changed it.

Doohickey deniers buying into their own confirmation bias drives me NUTS!

Anyhow; your pce will likely be in the right side. Read, (thanks to Tom); Post Page

 

[tomo]

Oil pools in the bottom, Bathes lower bearings, is pumped up through your screen first(?) then through your oil filter, out to upper portions and back down. Like a car. A circulatory system. Also, KLR's don't have a traditional "oil pan" but works the same. Somebody proofread this, I'm working on a COVID fog still
Great source for parts viewing:

2002 Kawasaki KLR650 (KL650-A16) OEM Parts, Babbitts Kawasaki Parts House

Shop our large selection of 2002 Kawasaki KLR650 (KL650-A16) OEM Parts, original equipment manufacturer parts and more online or call at (231)737-4542

www.kawasakipartshouse.com

2002 Kawasaki KLR650 (KL650-A16) Oil Pump | Babbitts Kawasaki Parts House

Shop online for OEM Oil Pump parts that fit your 2002 Kawasaki KLR650 (KL650-A16), search all our OEM Parts or call at (231)737-4542

www.kawasakipartshouse.com

2002 Kawasaki KLR650 (KL650-A16) Crankcase | Babbitts Kawasaki Parts House

Shop online for OEM Crankcase parts that fit your 2002 Kawasaki KLR650 (KL650-A16), search all our OEM Parts or call at (231)737-4542

www.kawasakipartshouse.com

 

[Br549rick]

the broken piece will probably be found at the rear bottom of the sump behind the drain plug. its too heavy(i think) to get sucked up to the screen....lots of smaller,light particles will though.

 

[pdwestman]

The bike sets on the side stand most of the time & idles, so the vibration would cause the part(s) to shuffle to the LH side of the inner cases and settle into any normal sludge.
A large bump could cause the broken part to bounce over the dividers. Or UP into the transmission gears.

Best access to the rear 2/3rds of LH interior case is thru the holes in the RH side, under the clutch.

 

[pdwestman]

Hi there, I just bought a 2001 KLR650 from the original owner who took great care of it, but was adamant that the Doohickey thing was no a concern so he never changed it.

If one looks closely at your pics, one can see that the original owner Never loosened the locking bolt to allow the spring to Re-Adjust the system either.
Only the one bolt position mark on it (Unless the remains of the locking lever was stuck to the case paint and it couldn't re-adjust)!

How many miles are on its odometer?

 

[CentralOregonKLR]

If one looks closely at your pics, one can see that the original owner Never loosened the locking bolt to allow the spring to Re-Adjust the system either.
Only the one bolt position mark on it (Unless the remains of the locking lever was stuck to the case paint and it couldn't re-adjust)!

How many miles are on its odometer?

55,000 miles young.. Paid 500.00 because it wasn't running and had no power. Turns out is was a broken ignition wire in the harness (at the connector) I traced out and fixed. Took me about an hour to get it running, and it actually sounds really good. No knocking, ticking or other indications it has any problems. I was in love when after sitting 3 years out side in the rain it fired right up after fixing the ignition wire. I have driven it about 5 miles, but wanted to get the doo done, and some other needed items (chain, rear brake hung etc.) So once I fish out that last piece of metal I will put some serious miles on her.

 

[tomo]

That's pretty amazing. If you're ever over to the wet side, I'll give you my 2002 seat (has a poke hole) . Start your maintenance list. fork oil, brake fluids, valve check, swing arm bearings, etc... Then start mods and buying add-ons.

 

[CentralOregonKLR]

That's pretty amazing. If you're ever over to the wet side, I'll give you my 2002 seat (has a poke hole) . Start your maintenance list. fork oil, brake fluids, valve check, swing arm bearings, etc... Then start mods and buying add-ons.
View attachment 40793

I would love that seat, and will be heading over that way in a couple months!

 

[SirMarksAllot]

Be sure to read this BEFORE you reinstall your oil drain plug 😉.

Common new KLR owner mistakes to avoid

Here is my list of "common new KLR owner mistakes to avoid" 1) Oil drain plug overtightening: it is relatively common for people to overtighten the oil drain plug.....usually to stop a leak after the gasket/washer has inadvertently fallen into the used oil or left stuck to the bottom of the...

www.klrforum.com

 

[CentralOregonKLR]

Well sometimes you win! Look what I found at the bottom front on the clutch side. I was going to forget it if I couldn't find it on that side, but I will ride a little more relaxed knowing it isn't in there.

So the take-away from this KLR newbie is: Doohickeys do break, big pieces fall into your engine, and your way better off replacing it sooner rather than later!

 

[gobradov1]

I wonder what the guy in the YouTube video would say to you. All a myth? Great you used the info of the knowledgeable!