[Damocles]

Maybe the doohickey (not the spring) DID get fixed!

That seems to be a common question [Did the doohickey get fixed on Generation 2 bikes?], so here's one answer.

Seems to me the video clip addresses a TENSIONER SPRING PROBLEM, in contrast to a doohickey (idler shaft LEVER) problem.

The distinction between spring and lever may be a fine one, but . . . the stock Generation 2 doohickey lever shown appeared to be in servicable condition. Rather, a slack tensioner spring appeared to be the deficiency.

An aftermarket coil spring, or a "torsion" spring (the latter with a Moto-Tooled notch applied to the stock doohickey) can be used with an OEM doohickey.

Thus, seems to me what we have here exhibited is a slack tensioner spring, in contrast to a failed doohickey.

Generation 1 doohickeys (the levers themselves) sometimes failed with catastrophic collateral engine damage. Evidence of any failed Generation 2 doohickeys (the levers, not the springs) remains scarce and elusive, I think hardly illustrated by the video clip above of a slack tensioner spring.

FULL DISCLOSURE: An Eagle Mike doohickey (with its superior fit, finish, and extended adjustment range) and torsion spring grace my Generation 1 KLR650!

 

[Damocles]

Your point is well taken, though, Damocles. I shall modify the title a bit...

Tom Schmitz, I appreciate the thread title revision, resulting in more accurate and precise prose!

And, I've no problem with anyone's lexicon whose nomenclature of "doohickey" includes idler shaft lever and spring only.

If the term, "doohickey," is an umbrella for the entire balancer chain tensioning system, other components may be involved besides the idler shaft lever and spring alone. For example, a dozen separate parts in this fiche comprise the balancer chain tensioning mechanism:

http://www.kawasakipartshouse.com/oemparts/a/kaw/500b5734f8700223e4796ac8/balancer

I consider the doohickey (idler shaft lever) and the tensioner spring as two separate parts. These components are identified and sold separately by Kawasaki, and marketed individually by Eagle Mike and other aftermarket vendors; that is, no "doohickey assembly" consisting of lever and spring exists, AFAIK. The doohickey-and-spring are not distributed as a "set," either may be replaced independently of the other.

Parts in the fiche: cap/bolt, idler lever/O ring, 7mm/lever, idler shaft (doohickey)/circlip-type-c 20mm/llever/washer, 20.3 x 36 x 1.5/spring/shaft-idler/sprocket-idler, idler/bearing-needle/spacer.

Generation 1 doohickeys (idler shaft levers) sometimes failed, disintegrated, broke, "grenaded." This malfunction sometimes resulted in catastrophic engine damage; cam chain de-sprocketing, bent valves, burst piston crowns, etc. Don't know of any Generation 2 OEM doohickeys with similar failure mode and consequent engine damage.

Spring issues surface, but as in the videoed example, without the trauma and carnage of the Generation 1 doohickey (idler shaft lever) failures.

 

[Damocles]

What, an ad hominem (personal) attack on me, rather than addressing the Generation 2 doohickey maintenance history issue?

I'm shocked, SHOCKED!

willys, I cannot tell you how much I value your literary criticism, and character guidance!

As a highly-renown KLR Guru, your remarks mean a great deal to me, and--I'm sure, to many others!

Thanks for serving as an example to which others may aspire.

BTW, while we're discussing aftermarket parts, what do you think of the Thermo-Bob?

 

[Damocles]

To the best of my knowledge and belief, no 2008 or later doohickey (idler shaft lever) has failed, nor has one been the source of any maintenance issues.

Spring tension issues have surfaced; the aftermarket torsion spring remains superior to OEM (stock) coil springs IMHO; even aftermarket coil springs appear superior to the factory originals, from reports I've read.

Full disclosure: Eagle Mike doohickey and torsion spring on my Generation 1.

 

[Damocles]

Wow, really good thread! I'm not sure if my '09 has been upgraded with the Eagle Mike kit but you can bet I'm going to purchase and install it just to be on the safe side.
:character00201:

Doohickey-wise, "safe" does not possess the weight on a Generation 2 that the term might on a Generation 1.

Some Generation 1 doohickeys grenaded with catastrophic collateral engine damage; however, I know of no Generation 2 (2008 and later)doohickey component failure.

Generation 2 spring tension issues have surfaced, with consequences ranging from inadequate balancer chain slack adjustment, to broken springs falling into the works with consequent trauma.

Checking spring tension on a Generation 2 is sound maintenance. Upgrading the doohickey might not be as critical as with a Generation 1, but offers superior fit and finish and extended adjustment range.

 

[Damocles]

Then in the later models they went to a cast piece that fractured and failed.

The "later models" (Generation 2, 2008 and later?) "fractured and failed?"

Really, Jack Moorhead? Please share your evidence of OEM Generation 2 doohickey(s) "fracturing and failing."

I know of no credible, verifiable evidence of any Geneation 2 OEM doohickey (idler shaft lever) failure; not saying it never happened (even the Space Shuttle failed), only: Would appreciate any example; and an estimate of the percentage of Generation 2 OEM doohickeys failing in service.

Once in and the bike was all buttoned up I was elated with the final result.

Only a question: What, exactly, was the final result?'

Regardless, I've found Eagle Mike to be a competent manufacturer, and a vendor of high integrity, in my own experience dealing with him.

FULL DISCLOSURE: Eagle Mike doohickey and torsion spring in my Generation 1.

 

[Damocles]

"What we've got here is FAILURE to communicate," justjeff!

First, I tried to CLARIFY these "later models" of doohickeys, "fracturing and failing."

If Generation 2, I welcomed evidence of this revised part's failure. Apparenlty, there is none (the failed doohickeys on the proferred video, I assume, are Generation 1s).

Fact: SOME Generation 1 doohickeys failed, resulting in catastrophic collateral engine damage.

Myth: ALL doohickeys must be replaced immediately, regardless of vintage, or their host engines will turn into pumpkins at the stroke of midnight.

Further, in my own defense, I clearly satated I had a geniune Eagl;e Mike doohickey and torsion spring in my GENERATION 1. I also saluted Eagle Mike's competence and integrity.

That said, I do not find Internet-fueled tribal knowledge myths useful.

YMMV!

------------------------------

Nonsense aside, the doohickey (idler shaft lever) was upgraded with release of the 2008 models, SEVEN inclusive model years ago. Any incidents of Generation 2 doohickey failures over this interval? If so, let's see the images and read the details! "Inquiring minds want to know!"