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Not trying to start trouble here yet, I have heard a good many stories about this problem on the KLR's. Mine is an 06 with 9k+ on the clock and everything seems the same as the day I bought it new.
On another forum I saw a poll on this problem and it turns out that a third of the owners had the problem and got the upgrade.

I do think that Kawasaki needs to fix this if 30% of these bikes are faulty. Yet at the same time if it only happens to third of the responders is there really a problem? Notice I said a third of the responders.

So is this a real problem for all the bikes or just a small number? I would think that by now the government would have gotten involved if the problem was as much as thirty percent of the bikes.

See what I mean?

You thoughts please.

Phil
 

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The only way to know is to go in and look. It will take less than an hour of your time to look. Just do it at the next oil change. Many owners did not know they had broken parts until they looked. Once in a great while the broken parts cause damage. The odds of engine damage on the 3007 and earlier are much greater than winning the lotto. The 2008 and 2009 won't adjust due to sloppy fit on the shaft and a spring that is too long. Disclosure - I make the aftermarket parts. Here are a couple of pic's of some of the broekn parts. I now have several more. Most of the time the system just doesn't adjust. NExt most common is one or both broekn parts. Rarest is the engine damae, which can include jumped camshaft tiiming. Sometimes it jumps enough to run poorly, once in a while the vales hit the piston. Once in a while a pice of the spring or lever gets intot he transmission or a bearing. This cause more severe damage, and one has to split the cases to rebuild the bottom end.

 

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You really can't go by a poll on a forum. When you consider the number of KLR's sold over 25 years.... Well, I imagine that's a lot of KLR's. The number of owners on all the KLR forums combined probably don't even come to 5%. If that poll says 30% of that 5% have problems, well, that's like 0.17% reporting the problem, but that's if all the members of every KLR site combined took the poll. Seeing as it's only one KLR site, you'll probably end up more like 0.05% when all said done.
 

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You really can't go by a poll on a forum. When you consider the number of KLR's sold over 25 years.... Well, I imagine that's a lot of KLR's. The number of owners on all the KLR forums combined probably don't even come to 5%. If that poll says 30% of that 5% have problems, well, that's like 0.17% reporting the problem, but that's if all the members of every KLR site combined took the poll. Seeing as it's only one KLR site, you'll probably end up more like 0.05% when all said done.
An internet poll is quite valid. It's a representative sample.

I've been into more than 300 engines, and I know. When you take the time to get into several engines, then you will know what is really going on. :)

Many dealer mechanics also say the KLR doesn't need the valves adjusted, or they can hear when they need adjusting, or some variance in that. I can tell you they are wrong. The newer manual says they don't need adjusting until 15K miles. I've personally been into them, and know that most bikes are out of specification long before that.

There are several issues like this, and it is not internet hype.

Just out of curiousity, how many KLR's have you opened up? :)
 

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Hey now, don't be twisting my post around. I don't know why people feel the need to do that. I never said anything about the problem not existing. I'm just saying a poll on a forum isn't an accurate representation. And for the record, I have one of your parts here and ready to be installed.
 

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I used smiley's hoping you'd know I'm not being testy.

I don't understand why you'd say an internet poll isn't representative. I think it is, just can't see why it would not be. It's actual experience of the sample tested.

all the best,
Mike
 

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I understand what your saying, but you have to consider the focus group. It's not like a live poll where a person is physically and randomly walking up and asking people to take it. On the internet, it's just there for whoever passes by and chooses to take it. People with the problem are more interested and more likely to seek out a poll like that so you end up with an impartial poll.

Sure, it's still information and extremely good to have, but it's simply not a valid representation of the overall problem.
 

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I have an 07 with 2500 mi. It is frustrating that this problem exist and I plan to doo it down the road up around 6 or 7k but I have to wonder if there are any high milers that have never done the doo and are still running strong?
 

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I have changed the doos in both of mine.Both 05s.One had less than 3000 miles and the spring was barely fastened.The other was ok @ around 7000.One has over 40,000 semi hard miles and no problrms.The other @ 8000 and no problems.I have a friend that when he opened his up they couldn't even find all of it with a magnet.He had around 40000 at the time.I like the peace of mind knowing that they have been changed out.It is a simple fix.The original piece that went on the shaft was a spot welded two piece ant that is what let go.Now it seems the springs are goin south.You can be in and out in less than 1 1/2 hours.I replaced mine with Eagle Mikes and have not had a problem.As far as polls go.Wouldn't/couldn't you take the total of the membership of a paticular forum,run the poll,then take the percentage of answers for that group and apply/multiply the answer for the total of klrs? The only way you could get within,say,+/- percentage is have a known number of owners.Not wanting any arguement or anything,just wondering how accurate it would be.I'm guessing that 30% is low.

Hang in there guys.Ridin weather (Good Ridin Weather) is almost here.Supposed to be single (2) digits here by the weekend

Mike
 

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I in fact just installed my studebaker doohichey with the torsional spring and I had a broken spring, now I am going to get a magnetic oil plug and hope the piece will show up on the magnet my bike is a 2006 with 2000 miles on it yeah it's a problem I love kawasaki's but come on people fix the damn thing.
 

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I understand what your saying, but you have to consider the focus group. It's not like a live poll where a person is physically and randomly walking up and asking people to take it. On the internet, it's just there for whoever passes by and chooses to take it. People with the problem are more interested and more likely to seek out a poll like that so you end up with an impartial poll.

Sure, it's still information and extremely good to have, but it's simply not a valid representation of the overall problem.
It's not an opinion poll, it's a data poll where the person has to have actually taken their bike apart then report their findings. The poll at at KLRWorld actually shows only 34% of 383 bikes with the tensioning system was working properly for 87 thru 07 models while 40% reporting some problem it. 57% reported that the spring in their 08's had no tension. This poll is valid and accurate.
 

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Today I saw two dohicky change outs one everything was fine and the other the spring was broken.
 

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Out of all the bikes I have seen opened up, about 1/3 have had a bad doo or spring.

Eagle Mike has seen A LOT of bikes opened up, and has assisted many guys and gals in changing out the doo's, along with any other thing on the KLR's.

I "was" one of the biggest skeptical s until I found a broken doo in my 8 month old 04 KLR.

To answer your question, yes there have been several bikes with high miles that the doo was good when it was opened, and there were some with less than 1000 miles that had broken doo's or springs. (that I have seen)
 

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I agree with the polls and the need to change it out no matter what!

But...it's your bike and it will be your headache is your's goes.....and if you don't take the advice of the more experienced owners out there...don't come crying after you find out that your DOO had fallen apart after telling us that you don't see a need to deal with it!!!

No...different than having Prostate cancer if it's in your family...IMHO....there is a 50% greater chance of getting this issue if your father has it....now...a sensible man would be getting it checked every year after he finds out his father has it...no?? If not...what flowers do you want on your grave?? Make sure you buy them yourself and have them delivered!!

You have many helpfull experienced KLR owners out there who have told their story about their DOO issues and you do what...?

Why some people need to question and argue over a prooven issue is beyond me?

Mine was broken and spring in bits in my engine when I opened it up around 4000kms...I bought it with 4000kms!!!


Rant over!!!
 

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Even if the doo on 08's is not changed the spring will need to be because it does not have enough tension in it for adjustment.

I changed just the spring on mine as a test but the fit of the 08 doo on the shaft is terrible and it causes vibration and wear. So it's a good idea to change it out altogether.

The torsion spring looks to be the best solution.
 

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'doohickey' balancer lever

Since I bought my '04/650 last June I have been wanting to do this mod and received as a gift for Christmas the 'upgrade'. It is the Studerbaker type.
My question if anyone can answer is, is there any particular difference in quality/durability between the Studebaker and Eagle or others.
Thanks for your thoughts.
 

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'doohickey'

The price tag on my upgrade package is $118.00 CDN. But will let you know how it goes as soon as I finish the "Crown Moulding' project.
 

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I in fact just installed my studebaker doohichey with the torsional spring and I had a broken spring, now I am going to get a magnetic oil plug and hope the piece will show up on the magnet my bike is a 2006 with 2000 miles on it yeah it's a problem I love kawasaki's but come on people fix the damn thing.
In my opinion you are not out of the woods yet. You do not have an Eagle doohickey or torsion spring and the Chinese products (copies of the not finalized Eagle product) you have does not meet the standards or quality of the Eagle products. Hopefully what you have will hold up for you and your KLR but if I were to buy your KLR those products would be the first thing I changed.
 
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