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Hi Everyone

this weekend, i'm doing my Doohickey on my 2013 klr.

and i have a problem, something i have never seen on any videos or pictures of "how to" Doohickey

it seems the tension chain is rubbing the low end of the case, and groove the metal.
see pictures below

I bought this used bike 2 years ago,
I thought the Doohickey maybe had already been changed, because there is an orange gasket silicone all around the cover, but it's a "OEM" Doohickey and spring inside.
may be changed by the dealer ?

its seems something is not not well installed, but i don't know what.
i have remove the tensioner sprocket, and everything looks OK according to my Clymer book.
but i am not a specialist... it is my first Doohickey change

has anyone seen anything like that ?










how to make it stop rubbing ?

Thanks
and sorry for my bad English, i hope it is understandable.
moosehead,
In the 1st pic,
I can see the oem spring is still attached to its anchor post. Was the other end still attached to the lever arm, or was the hook broken off? The spring & lever arm tried valiantly to control the slack with an un-locked doo-hickey, by evidence of missing paint (pics 2 & 3) under the spring. At least for as long as it could.

And yes that area that is totally missing paint (looked sandblasted, behind the doo) was also because of running with a loose locking bolt.
Was the locking bolt loose when You took it apart? Or tight in its maximum tension position, of 1st pic?

Is your engine back together YET?

If not back together, maybe you can grab hold of the upper rear weight or shaft and try to feel for slack in those bearings.
Tom Schmitz lost his 2008 engine because of the upper rear balancer bearings failing.

3rd & 4th pics,
If the engine is not yet together, one can use a Dremel burr to relieve that case bolt boss under the chain. That area is Solid behind the threads of the bolt. Of course it takes a lot of rags, tape and vacuum cleaner to suck-up as much cuttings as possible while cutting and clean up the final mess, before reassembly.

If the engine is not yet together, do you have pics of the New Doo-Hickey & Torsion spring, Installed? So we can see how much potential future adjustment travel is available?
 

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Discussion Starter #22
when I opened, the spring was attached on both sides.

the adjustment screw was tight, but easy to unscrew.

and the OEM Doohickey was in the picture 1 position, completely to the front of bike


the engine is now reassembled.
I took that picture of the new doohickey before reassembled
is my future adjustment correct?




I think the engine was opened before I bought this bike.
there was orange silicone gasket in addition to the factory gasket. it didn't look like a factory job.
the spring may have been broken and replaced by an OEM.

and also, when I put a little tension in the bottom sproket (pic 2)
by turning it a little clockwise
it seemed to me that the chain was going down, in the rubbing groove
for the chain to go back up, I had to turn counterclockwise.
is it only because the engine doesn't run?
shouldn't the tension make the chain go up?

maybe I'll open it again next winter,
to make sure the damage is not worse

Thanks
 

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For only 21,000 miles of useage, that is the farthest that I have even seen an EM Doo-Hickey rotated to, either on the internet or in person.
 

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Discussion Starter #24
For only 21,000 miles of useage, that is the farthest that I have even seen an EM Doo-Hickey rotated to, either on the internet or in person.
Outch.

according to you, can I still ride this for a lot of miles?

with the new Doohickey and torsion spring installed, will the rubbing stop ?
 

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Outch.

according to you, can I still ride this for a lot of miles?

with the new Doohickey and torsion spring installed, will the rubbing stop ?
Provided that nothing else is or goes amiss and the Doo-Hickey is allowed to re-adjust the chain slack about once every 5000 miles or so, it may still run to the 100,000 mile / 160,000 km + mark.
Only one way to find out, ride it.

With the Doo-Hickey locked down with the bolt to 70 inch pounds there can not be any movement or rubbing.

Welcome to the forum & Ride Safe!
 
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