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I would cost too much to go back and do 20 years worth of motorcycles, and then they would also have to admit fault. I don't see that happening. The doo is not a very difficult thing to change out. Patience and following step by step procedure is the biggest thing.

Here is the procedure:
http://www.klr650.marknet.us/Doohickey.pdf

Parts can be obtained at:
www.arrowheadmotorsports.com
www.klr650.com
www.tpimotorcycleparts.com

I know there are more places out there, but arrowhead is where I like to order from. If we can be of more help, don't hesitate to ask.
 

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Discussion Starter #3
Thanks

Thanks for the help. I am not planning on doing until this winter. I should have enough information compiled by then for it to be an easy (but challenging) project. Thanks again.
 

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I recently purchashed a 2008 klr. How hard is the doo-hickey upgrade to do ?
I cant help but wonder why Kawasaki dosent recall the bike or fix the problem at the factory end.
2008 has an upgraded doohicky already - I just used the 2008 part to fix mine...

MUCH different part then the stock 2005. Guess the spring may be an issue - but have not read that 2008's are having the same issues.

Sean
 

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Yep 2008's have shown a broken spring and a doohickey before a 1000 miles like many of the previous ones. The doo itself on the 08 is the only thing that was upgraded, but there is still a good amount of slop in the fitting to the shaft in regards to the good Eagle Mike after market doo.
 

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Roger that but the spring is still a problem. No tension on any of the ones we have done.

John
 

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Doo-Hickey??

:confused: I have an 08 with a little over 2000 miles. It seems to be running fine. What is the doo-hickey and how do I know if mine needs to be replaces?
 

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Go up to my post above that shows the link to doohickey procedure, it will show you what it is and how to change it.

Change the doohickey no matter what. Have seen them broke with under a 1000 miles and some have never broke at 30,000 miles, but if it does break or the spring breaks there is a chance of fatal engine catastrophe and for $40 for the doo, it's well worth spending to have peace of mind knowing it is fixed and your safe.
 

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Yep 2008's have shown a broken spring and a doohickey before a 1000 miles like many of the previous ones. The doo itself on the 08 is the only thing that was upgraded, but there is still a good amount of slop in the fitting to the shaft in regards to the good Eagle Mike after market doo.
the 08 doohicky was good to go, no slop and greatly improved from the stock part...

I did use a different 37mm spring - the stock spring was long on my 05.

Engine runs much smoother since I did the upgrade, and now that I modified the cover I can check the spring tension much easier.

I have an extra side cover and gaskets that I am toying with eBaying...will drill the appropriate hole out for the side cover mod I think before I list it.

Sean
 
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