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Discussion Starter #1
I do not have a KLR but I'm trying to figure out this technical terminology. I'm guessing it has to do with the cam chain tensioner, is this a magical aftermarket replacement?

What is the problem with the stock setup and is there any feedback from Kaw. Does the problem still exist on the 07"s?

Thanks
Rich
 

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The "doohickey" it the counter ballancer lever. Yes it is a cheap part Kawasaki puts in the KLR, about 1/3 of the KLRs wind up with a broken doohickey in the first 10,000 miles. Some cases have been reported that the pieces have locked up the motor by getting caught in the chains.
Kawasaki refuses to admit there is a problem, and my guess is because it costs them no money, they don't want to admit there is a problem. Most people change them out without Kawasaki's knowledge. Yes it is the same piece of crap on the 07 s.
A guy "Eagle Mike" in San Daigo CA makes a replacement lever that is top notch. He sells them for around $40, and it takes about two hours for the novice mechanic to change one out. Several people have posted directions on how to do the doo.
 

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You will get lots of input about using a search funtion but tie "Doo" is the tensioning mechanism for the balance shafts. It is prone to failure by the spring breaking or the lever itself breaking. It is cheap and easy to upgrade and has not been upgraded by Kawasaki yet. Look around this forum and you will find a wealth of knowlege.
 
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