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Read a thread on here from a fella who doesn't really believe the doohickey failure. Not all fail. Here is mine - Another doohickey replacement. 1990 Tengai with 3500 miles. I bought this bike used with 3400 original miles. You can see from the picture that the bolt dug into the slot. No adjustment. With the adjustment bolt completely removed, it moved over about 1/2 inch. Spring was intact. Eagle replacement parts used with the longer of the two springs. Tools, seals and rotor bolt also from Eagle. Adjustment bolt replaced with newer style bought from Arrowhead. Although I purchased new seals, I kept the old ones on as they were in perfect shape. The Tengai manual says to torque rotor bolt to 145 ft/lbs, but upon advise I set it to 130 ft/lbs, which is the standard for KLRs. Thanks for calling me back Mike. Your help is invaluable and you stand behind your product. All the chatter is now gone. Valve adjustment is next.
 

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Mine was the exact same way. And Mike saved the day with you too. Me too. Thanks, Mike
 

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I just replaced my doo at 1200miles on an '09. No problems with the unit itself
but the spring was completely relaxed. All the coil windings were touching. It had
never been adjusted,nor could it ever, not even once. Iused EM's longer spring and
it took a fair amount of stretch to get it in place. Whoops. My bad. Used the longer
of the two supplied. Still, it has a few adjustments in it before needing the shorter
spring installed in another 50,000 miles or so.

What I didn't like about the "upgraded" stock unit was the cheesy casting. (I"m
a foundry guy and know crappy castings and there also was no machining done
to the sliding face of the part. That's the reason the bolt bit in to yours and never
moved. The bolt machined it's own lil' happy spot.

Sad. Mine would have been excactly the same after loosening it once then retorqued it.
Glad it's outta there and Kudos to Mike for a truly well made product.

CheapMark
 

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They must use some pretty shitty casting house (read fly-by-night China or whatever). In my biz we use machine faced heatsinks for our prototype cellular radio base station amplifiers, then go to a "precision" casting for production. The specs are pretty darn tight on the casting and I was hesitant to go with cast heatsinks at first but we've been using them in production for about 5 years now and no problems.
 

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Rotor torque value.

Gen1 (1987-2007) = 130 foot pounds
Gen2 (2008 to current) = 144 foot pounds
 

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After two years with all the stuff I finally manned up and did my doohicky last week. Let my self get intimidated by some of the problems I read about with stuck and stripped rotars and dropping washers doun into the motor when the idler lever shaft got pulled out. I read all the doohicky install guides I could find (4 total) and watched the how to vidio on you tube and everything worked well. My gaskets came of in good shape so I reused them. The outer gasket leaked at the bottom when reinstalled so I had to drain it again and put it back together with yama bond (should have done that in the first place as suggested in one of the write ups). No leaks now. My old doo was intact and the spring had tention. I was a little disappointed for some reason. I wanted to post mine was broken but it wasnt and it was still doing its job. Not all break but I now have peace of mind and wont hesitate to adjust it at every oil change. I have never adjusted it for fear if it was broken i might drop something. It now sounds much quieter and seems smoother. I have an 05 with 5500 miles. I used an EM doo and used his torsion spring. Notched the top of the doo to catch a coil as he now suggests. Again my aprehention was unfounded. It went smoothly other than my leaky gasket. Also installed my thermo-bob I have had for almost 2 years. Again no problems and it warms right up to just below halfway on the guage and holds dead on even at just an idle in my 35 degree shop.
Feeling content and pleased with myself.
 

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Replaced my Doo after 8k miles. Mine was not broken either. Wasn't as hard as I had expected to do.
 

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Replaced my Doo after 8k miles. Mine was not broken either. Wasn't as hard as I had expected to do.
But was the spring doing anything. Most of the Gen2 doohickey springs can be easily removed by hand.

You are safe now with the Eagle doohickey installed.
 
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