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This part seems to cause a lot of problems but I don't know what it is and what the problem is. Please fill me in. Thanks.
 

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If I read the instructions correctly, when I order parts for my doohicky upgrade, I will need the replacement dh, new spring/springs (either torsion or regular), probably the two new housing gaskets, and a torsion bolt?
Tool wise, just the "special wrench" for the torsion bolt, and a torque wrench?.... along with all the "normal" hand tools/wrenches, etc...

Does that sound about right? I see the potential for an "all items included package" from Eagle Mike. (at a discounted price, of course)
Unless, of course, he already offers one... I need to go check out his website.
 

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The housing gaskets (knock on wood) alway come off in one pc. if you take the cover off carefully... We typically give the old gasket a light film of RTV before putting it back on.. We've had a spare gasket laying around since the beginning and have never needed it.

Tools are available, usually for the asking and the price of shipping from someone who's done the doo.. This includes the wrench and torsion bolt..

I'd recommend putting out a post to see if some in DFW area has tools and would be willing to assist.. You'll need the doo and springs (either torsion or regular) and it's a good time to change oil since draining oil makes less of a mess. Basically, you'll need $40 worth of parts, and someone local who's done it before, as well as some borrowed tools..

As far as a torque wrench, hit up Harbor Freight and pick up a cheap one.. Good thing to have on hand, anyway.

We typically do the Doo, and also replace subframe bolts at the same time, but the bolts can wait.. Not sure if the 09' has an issue with subframe bolts, but the pre-08' models could use the better hardware if you're hauling a passenger or have bags or a top box. Basically, cheap insurance..
 

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I've got a couple of Proto torque wrenches... I'm not sure if the "big" one goes up to 100+ pounds or not, though.

I thought about fabbing my own wrench.. what is it, a 28mm, or some such?

I might just try it without the new gaskets.. it would sort of suck if they tore up, and I didn't have any to replace them with, though. Another week long wait.. although I guess the Stealership might stock them.
 

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El Cheapo' made in India (Poonjab?) 1 1/4". Torch, vise, hammer = instant special tool.

My gaskets came off clean and were reused. No leaks after 2,000 miles.

 

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El Cheapo' made in India (Poonjab?) 1 1/4". Torch, vise, hammer = instant special tool.

My gaskets came off clean and were reused. No leaks after 2,000 miles.

Yes, that is exactly what I was thinking. Pawnshop tool, oxyacet torch... yee haw.
POON-jab? I'm not even gonna TOUCH that one...
 

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hornetguy,

Since you live in a larger city you might want to put a Tech Day together and get some assistant / support from other(s) that have already completed the upgrade. Tech Days are usually a fun event and you get to meet other KLRistas. Plus they can bring their tools and you don't have to make them.

Do yourself a favor and buy your parts from EagleMike, the guy that makes the Doohickey and supporting parts. He also sells the other items needed for the upgrade. Or load your stuff up and come to the Julian CA (SoCal) Tech Day on October 10th. You wouldn't be the first person to show up from east of CA.
 

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yes, a tech day is a thought..
I don't think I'll have any problems with the actual "doing" of the upgrade, I was just a little confused about what most folks were actually having to replace during the procedure. Most of the time, it's a good thing to have more than one pair of eyes and hands doing a job.. if nothing else, it's good to just have the "moral support" from someone that says, "oh, yeah, mine did that, too.. "
From everything I've read, I'm definitely planning to go with Eagle Mike's stuff. I've never dealt with him, but the consensus is that he's hands down the best, quality-wise, and customer service-wise. To me, word of mouth recommendations are worth listening to.
Price, for the most part, is a secondary consideration.
 

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From everything I've read, I'm definitely planning to go with Eagle Mike's stuff. I've never dealt with him, but the consensus is that he's hands down the best, quality-wise, and customer service-wise. To me, word of mouth recommendations are worth listening to.
Price, for the most part, is a secondary consideration.
That's the cool part about Mike's stuff.. Same price as the cheap imitation, and I've never read a bad thing about his workmanship or customer service.

He's the only person/company who's ever returned a call to me on a Saturday afternoon, only to appologize for taking an hour to call back.. And then was extremely helpful to boot.:)

I only wish the torsion spring adjuster had been an option when I did mine. At the time, he hadn't designed one yet.
 

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POON-jab? I'm not even gonna TOUCH that one...
OT, Sorry.

This is the guy you talk to when you have computer problems ........."Oh, pardon me please, there is a cobra in my cubicle". This one is somewhere in Bombay, not Punjab (spelling corrected).



Hornetguy, PM sent.
 

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If you decide to install the Torsion spring (my recomendation) a 4" handheld tac puller will make the spring connection simpler.

http://www.homedepot.com/webapp/wcs/stores/servlet/ProductDisplay?jspStoreDir=hdus&catalogId=10053&productId=100034526&navFlow=3&keyword=tac+puller&langId=-1&searchRedirect=tac+puller&storeId=10051&end[email protected]2a910b25&ddkey=Search

or you can be like me and buy one then find one in an old toolbox you bought at a garage sale.
Thanks for the heads-up... I THINK I have one of those, but if I don't, I have several sacrificial screwdrivers that can be dremel'd and filed into shape...
I'm forever "modifying" tools to fit something they weren't designed to do.
If I had a TIG welder, I'd be REALLY dangerous.
 

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I think I talked to two of that guy's sisters today, trying to straighten out a Capital One card account that I thought I had closed out about 3 months ago. "What did you say? I didn't understand that... can you repeat that?"
LOADS of fun. I don't speak Pun-jab-ese, and they certainly don't speak redneck..:36:
 
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