!BEWARE ! Kawasaki KLR 650 , another doohickey video . Part 1.

!BEWARE ! Kawasaki KLR 650 , another doohickey video .
This video shows an underlying reason why the doohickey spring is not under tension . This will probably not apply to everybody , it's just a problem that I found on my KLR .

[@jurgenbuchelt4384]

You are mixing up cause and effect. The one and only reason why the guide rails are worn and broken is because the chain ran with a lot of slack for ages. The trails do not add any tension to the chain, they keep it from slapping (the rear one) and they keep the chain from climbing the crank shaft sprocket )for some time) if the tensioner does not work or is broken..

[@billwalsh6566]

Great info. I've never see this on any others I've watched. Many Thanks

[@listairgin]

Great explanation of what many people can overlook. Thanks so very much for taking the time to explain this. Brilliant video 👍

[@ShaunMurray63]

Thanks , I hope it will be of use to people.

[@cyril.engineering]

One thing to note. I bought a 2017 new as a burner for a bad commute. At just 7000 miles and three months my spring was identically loose. My guides were okay. I think the moral of the story is it's a multi tiered issue. I wonder if some bikes might even suffer guide damage from too much slop.

[@donyboy73]

good explanation

[@RobRidesCarolina]

Even if it's not the exact same year and motor, still very interesting information. If I do the doohickey, I'll definitely check the guides for wear. It will be interesting to see what your new guide looks like, and how it's replacement alone would affect the chain tension. Thanks.

[@unclefranj8460]

Fantastic! Thank you for your diligence. Looking forward to the "second part".

[@chadevasiuk4643]

Thank you sir.. watched this a while ago and it took me some time to find it again.. I am balls deep into this KLR, still love the hell out of him, and now I know what he needs. Thank you you, Thankyou thank you

[@ShaunMurray63]

Sorry for not replying earlier it seems that I am not receiving notification about comments on some of my videos from youtube. Thanks , I hope it is of use to ypu.

[@GreaseAndGravel]

Brilliant video, thank you for explaining that! I am glad I saw this before getting a KLR again!

[@clivegreenall309]

Hi Shaun, Thanks for sharing this info. I also have a KLR650 and have watched loads of "doohickey" replacement videos, but not one has mentioned these chain guides. I'll bear it in mind. I'll look for your next video. Regards from S Africa Clive

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. Yes it need investigating properly.

[@yomommaahotoo264]

About time someone posted about the problem tather than just the symptom.

[@ShaunMurray63]

Thanks , I hope it is helpful .

[@jaspertaylor7455]

Thank you for the information. I haven't taken my KLR650 apart yet, but I've heard about the " doo hickey", and this is one of many. THANK YOU, KINDLY...

[@alphashifter2207]

Doo-ing it today...Will check the guides, thanks to your video. Cheers!

[@northeasterndirtandpropert7974]

Good job,thanks for the vid,Im onto part#2.

[@jrfsailing07]

Thank you Sir!!! Great video! Like many others I bought the doohickey with the torsion spring and didn't check the guides. John from Colorado.

[@ShaunMurray63]

Thanks for your comment and glad you liked the video.

[@alanreilly9056]

Thank you for excellent explanation

[@ShaunMurray63]

Thanks I hope it helps.

[@jerrycrum6404]

Great info thank you for the insight will help a lot of us from making a half ass repair Thanks again Subbed

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. Thanks for subbing and glad the video is of use to you.

[@andrewheadland50]

With all the videos on this subject no- one has ever looked into this problem. Thanks again for sharing this, I don't own a KLR but this information is the best because there's always a reason why things happen & the manufacturer won't change things 👍👍👍👍

[@ShaunMurray63]

Thanks for your comments and I hope this video may be of some use to you in the future.

[@jimo199966]

Thank you the amazing and informative videos which diagnosed the issue of the loose cam tensioner and damaged chain guides. Your trouble shooting and explanation will doubtless save people from destroying their engines. A full inspection of the chain guides should now be a maintenance and inspection item. I'm definitely going to subscribe to your channel. Cheers and Happy New year👍🎉

[@ShaunMurray63]

Thanks , I'm glad it is useful to you.

[@malcolmnuttall3165]

It is not a cam tensioner that's on the left side rear of the head outside it . It's the counterbalancer chain

[@boxerreadventure8152]

Thanks mate for taking the time to fully explore the "Doohickey" problem and highlighting the "sleeper" worn crank guiderail issue

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. No probs.

[@nandutzu]

Thank you very much! Excellent explanation!

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. Thanks hope it helps.

[@TitanFlare]

Thanks for the video. I couldn't stand all the companies trying to push this upgrade down my throat by selling their $50 kit, but nobody ever explains why it has to be done or what causes it to go bad. Thanks for answering the why

[@ShaunMurray63]

Thanks , hope it is of use to you.

[@misfit8915]

Thanks. I could see everything you were showing. Well done

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. Thank you I glad it is useful for you.

[@trueamerican1576]

My guides were good my chain was tensioned but my doohickey was splitting half on the u-shaped part that goes around the tensioning shaft. Both of those little arms were broke. If I would have done the factory recommended maintenance and loosened the adjusting Bolt I would have had slop and pieces in my crankshaft. Definitely do the upgraded doohickey with a torsion spring but that is a great idea to check the guides.

[@Desertduleler_88]

Top tip, I'll remember this when I get my KLR.

[@ShaunMurray63]

Thanks.

[@bruhhhhh718]

amazing I'm really grateful for this

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. Thanks and hope it is of use to you.

[@ShaunMurray63]

Thanks for the comment , hope it can be of some use , the next video may late next week as we are awaiting some parts.

[@adventurevin7600]

Well...I learned the hard way. I wish I saw this first. I am already onto my 2nd Gen 1

[@scotfield3950]

Thank you

[@johnurquidi6441]

Need to send this video to Kawasaki and hopefully they will address the issue

[@moto_biker]

Excellent video 👍

[@ShaunMurray63]

Thanks.

[@jared3966]

Great info!

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. Thanks hope it's useful.

[@brett2070]

fantastic Video Shaun,,i havnt been show,n that before,,,,thx for the advice,,,

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube.Hope it helps.

[@skizzo19761]

You are a good ....Mate! Thanks

[@ShaunMurray63]

Thank you.

[@strongdelusion9442]

Well done mate!

[@ShaunMurray63]

Thanks.

[@johnmitchell8925]

My spring did brake in half on my 2003 at 10k miles and I changed my oil every 1k miles and always ajust ed the chain at intervals. Bought the bike new bought a new spring installed it and no more problems

[@nikduffield5457]

Did mine recently on a complete strip down my chain guide was the same, you'll find the rest of that guide in the little mesh filter below the clutch on the other side of the motor!! My spring was broken into a myriad little bit's so I had to split the crankcases to retrieve all the bit's laying in the bottom of the engine...It's well worth doing as you get to de-coke the cylinder head and check any other parts at the time. .

[@ShaunMurray63]

Sorry for not replying earlier it seems that I am not receiving notification about comments on some of my videos from youtube. Yes well worth the effort.

[@todtiger]

great vid

[@ShaunMurray63]

Thanks for your comment , it should be of use to somebody hopefully.

[@jamespelczynski8347]

Spot on chap

[@ShaunMurray63]

Thanks

[@pyroboobysmith359]

Excellent and informative video, but I had a pounding headache from all the dog barking.

[@ShaunMurray63]

Glad you found the video informative and yes the back ground noise can be a real nuisance at times.

[@tbillyjoeroth]

hahaha

[@brettdemauna9994]

I've just recently a coupler yrs back done the doohickey (Eagle Mike) upgrade on my 2011 klr650 but not to this extend, it's amazing how a 30+ yr old engine amidst Kawa still reproducing it up until now without even cranking more internal engine upgrades essentially now consumer's and aftermarket products were tendered like their second diagnostic upgrades to fix their infamous doohickey 30+ decades design flaw product. Hi! I'm from Nauru, please.. Google it (Nauru) and you'd probably wouldn't believe how a tiny dot speck country in the middle of the Pacific could quick brief KZbinrs regarding classic big sports and dual sports bikes we'd previously owned. They were mostly from Japan brands hence even some few moderate handful of other exotic unique brands like Harleys, Nortons literally to name a few. Those heydays 70s & 80s I've even spotted 1st gen Goldwing, 1st gen spoked wheel Gpz-900, Kawa Z1R 1000, Gpz-750 factory Turbo, Gpz-1300 six, CBX-1000 (my favorite) with several coupled with US built American built aftermarket Turbo spool, and last but CERTAINLY not the least, Suzuki 1st nor 2nd gen Hayabusa 1300... the list could go on but apparently I wouldn't wanna miss some of my other favorite models of sports bikes but there are a lot more to reveal than that I'd probably missed track to most hence there were basically pretty much much more than to these fewer lots that ive just mentioned. Anyway I've actually enjoyed reading your 1st post I come across, However I've even also just experienced that your article opened up a new frontier for me of more that not just the doohickey as the only "major culprit" klr650 flaw but there are a lot more to it, literally. I salute YOU and I'll definitely search for your other part 2 post. Now I'm thinking of a 2nd tear-down check of already fixed doohickey and most definitely also on those balancer chain guides. Keep them OLE KLR's rolling. Thanks so much well appreciated.

[@ShaunMurray63]

Sorry for not replying earlier it seems that I am not receiving notification about comments on some of my videos from youtube. That's a hell of a lot of bikes , Jused googled Nauru and you are in the middle of knowhere , this is the follow up video and thamks for your comment, kzbin.info/www/bejne/iXrJk2CnbrKUpac

[@dirtracksmotoshop]

I bought a brand new klr 650 in 2012 and had the same problem,zero tension on the spring,everybody should check this even on a brand new bike.

[@pinkiewerewolf]

Are you saying that a brand new KLR 650 had worn and splitting guides or that it wasn't tensioned correctly at the factory?

[@Biglug8888]

My '03 had only 3k miles and the doo was broken! I was fortunate to find all the pieces. Put in a Eagle Mike doo w/ torsion spring and took care of the vibrations on the freeway! Great video thanks

[@Ralphsleep]

Top stuff

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube, Thank you.

[@MrPepper312]

Update, I now have a 2023 KLR with 1033 miles and it has a ticking sound from the engine. Took it to my dealer and they took it in shop and 30 min later said they inspected the tensioner found nothing wrong and reassemble everything. BULL S..T. No way they could have done it in 30 min. Will never go back to this Kawasaki dealer again.

[@BikerGirlTraveler]

Very nice! I am thinking on buying the 2022 KLR650 when it's released in about three months. I wonder if with all the updates to the new bike if Kawasaki fixed this problem. I know they the clutch release bearings, which for what I've heard it was another issue with the bike. Part of the problem of buying an ungraded bike is that you have to wait and see what common problems were fixed, which problems weren't, and if there are any new ones that weren't there in prior years. Specially with as many changes as Kawasaki did to the bike in the two years they discontinued production. I a, planing a road trip through Central and South America and want a bike that is as reliable as possible. I was thinking about the new 2022 model and have it retrofitted with aftermarket parts any known issues right off the start to prevent any problems from developing. The last thing I want as a female solo rider is for my bike to leave me stranded on some lonely road in the middle of nowhere in some third world country.

[@ShaunMurray63]

Hello Yaslina , I would like to think all the problems that the older models had have been ironed out and the the new models are very reliable and I am sure they will be , It sounds like you are going on a fantastic journey and I wish you a safe and enjoyable passage through the south americas , all the best and stay safe. P.S. will you be filming and documenting your journey.

[@johnambro7181]

Absolutely great point to be aware of Shaun, I am looking to buy a klr and now the real truth to potential failures is completely apparent. Excellent update to the design wear flaw. This should be a service bulletin by Kawasaki , update the doohicky and replace the guide blocks. Thanks' for showing us the way. At what mileage did this occur to you? Cheers.

[@ShaunMurray63]

Hello John , the bike had 24 thousand miles on it at the time that's about 40 thousand kilometers depending were you are in the world and the bike was made in 1990. Yes you are correct in saying it should be a service bulletin and if you come across this issue with your future KLR we would advise you to change the chain as well. Thanks for your comment.

[@ORflycaster]

How what year is the bike in the video, and what was the mileage for that much guide wear. I just bought a KLR with 3K miles and plan the replace the doohickey and spring, but I'm wondering if I'll need to order guides too. Obviously I can check while I'm inside the engine, but I'd like to minimize the downtime.

[@anthonyperez9802]

Brilliant deduction old boy.

[@ShaunMurray63]

Well thank you kindly sir.

[@dbdb4274]

Any help I have a 94 klx650 took the cdi out plugged it back in now the bike won't start or spark... But the cdi will start a diffrent klx when I plug it in

[@goodwinezone2320]

What was happening before the repair? In other words what caused you to open bike and look for problem? Noise? Not running correctly? Thanks.

[@jbrizz99]

I think that worn guide is a product of the lost tension not the cause. If the chain is correctly tensioned the guide should not or should only barely be touching the chain. The plastic guides are never designed to take the chain under load as they'd fail almost immediately. The real cause is elsewhere.

[@ShaunMurray63]

The chain was worn and stretched.

[@unclequack5445]

How much is a new balancer chain?

[@aktrapper6126]

Great video and excellent content. Makes me want to tear into my KLR and have a look. How many miles does this bike have on it and should I be concerned at 5,600 thousand miles?

[@ShaunMurray63]

Hello and thanks for the comment , the bike had 16400 on it at the time would have thought yours would be ok at the moment but could be worth cheking it out if it worries you .

[@yomommaahotoo264]

Just curious - over and above miles, does the frequency and quality of oil changes effect the timing chain wear?

[@ShaunMurray63]

Yes it could very well do.

[@paulward9553]

So is this just wear and tear from a properly tightened/maintenced chain, or is it wear and tear from an improperly maintenced chain? How often did you adjust the Doo? Just curious if I am religious with maintaining chain tension if the guide will wear as bad.

[@ShaunMurray63]

Yes it's just wear and tear from what was a properly maintained chain but over time the wear on the guides e.t.c made the need to replace everything , the doo adjusts itself via the tension on the spring but after a period of time it ran out of adjustment and wore away at the guides.

[@paulcondie2520]

I still have not seen a single picture of one imploding due to the issue. I get it, in fact put an eagle mike's doo on mine but????? Lol. I checked all my stuff as well. All good. Just saying.

[@whereswaldo5740]

How many miles are on that bike?

[@turdferguson5108]

KLR riders around the world are shitting themsleves now - they didn´t check the chainguides......... Great job lads.

[@ShaunMurray63]

Haha, thanks .

[@unclequack5445]

Sir the loose doohickey wore the chain guide out to begin with.

[@ShaunMurray63]

In a nutshell , yes that is what happened.

[@ericscaillet2232]

@@ShaunMurray63 so its a catch22 where the dohicket is still at fault but not at first, where woud its setting be with new chain and guide and can one run the bike without the counter balance baring the water pump operation.

[@firegrunt03]

Ty from Houston. What about if that little screw adjustment breaks due to over torquing??? like some dumbasses did. ...Me...lol

[@frankrightbrain]

Thanks for this tutorial. What year is this KLR and how many miles are on it?

[@ShaunMurray63]

The KLR is a 1989 with 24k miles or the equivalent of 40k kilometres.

[@frankrightbrain]

Mine is a 2011 with 22k so I need to look at the chain and guides also

[@boxerreadventure8152]

More worrying still was the NEW tension spring was longer than the old one... WTF Kawasaki ?

[@DanteFox]

This is good to know. What is the year and the millage or K's on the bike?

[@ShaunMurray63]

Hi, it's a 2001 with 25000 miles on the clock.

[@ShaunMurray63]

the engine not its original one has done 25000 miles

[@spencervidal3168]

How many miles did that bike have on it? My 2nd hand gen 1 has 28000 miles and am wondering if I should replace the balancer and cam chain guides. As well as the doohickey.. Thx.

[@ShaunMurray63]

Hello , at the time the bike had 16,500 miles on it ,

[@spencervidal3168]

@@ShaunMurray63 Thank you, for the info. I will probably get a new set for replacement thanks..

[@bri1360]

Think you found the real problem so you actually need a smaller spring and replace them guides every so often how many miles do you have on that bike

[@ShaunMurray63]

Yes a smaller spring indeed and keep a eye on those guides , the bike at that time had done 26000 miles or about 40000 kilometres .

[@tizianocrivellari9702]

Bisognerebbe girare in bicicletta più tranquillità con tutti quei guasti oppure aspettare che tolgano tutti i difetti

[@MrPepper312]

Has Kawasaki fixed this problem on the 2018. I just purchased mine and is not even broken in yet.

[@ShaunMurray63]

Hello, I don't know if Kawasaki have fixed or upgraded the problem.

[@ericscaillet2232]

surely the chain guide should still be fine.

[@MrPepper312]

@@ericscaillet2232 would not hurt to order new guides for the future and find a shorter spring.

[@chadkline4268]

It seems like you did not update this video after you got new chain guides. Can you please inform the viewers if new chain guides fixed the problem of no spring tension?

[@ShaunMurray63]

Yes it's all in part 2 on my channel.

[@chadkline4268]

@@ShaunMurray63 ok, I did look but did not see it. I will look again.

[@ShaunMurray63]

@@chadkline4268 No probs Chad.

[@easternshoreblinds9477]

How many miles did that bike have on it?

[@ShaunMurray63]

24 thousand miles at the time .

[@bryanakathefixer8366]

What year bike is this ?

[@ShaunMurray63]

1989

[@dejanmeki]

what was milage on that engine ?

[@ShaunMurray63]

It had 16.5000 miles on it at the time.

[@Ur_clickbait_is_trash]

Part2?

[@ShaunMurray63]

This is part 2. kzbin.info/www/bejne/iXrJk2CnbrKUpac

[@todtiger]

Where is the unit shaun ?

[@ShaunMurray63]

Hi Tod tiger , it's my brothers unit in Lydgate in Tod.

[@DefencelessDuck]

What was the miles on this bike if you remember?

[@ShaunMurray63]

Hello , it had 24k on it I think at the time.

[@DefencelessDuck]

Shaun Murray thank you for the reply It gives me somewhat of an idea on how many miles the chain could last. Unsure of how a chain of that thickness could get so stretched. I purchased an 08 klr for 1000us from an old friend who fell ill. He will be okay but he can’t ride anymore. 6300km original stock everything. I have not opened it up but I did do an oil flush since it had been sitting 7-+ years I’ve put a few km’s on it and I think it runs great. I really appreciated this video, since nobody talks about WHY they have to do the doo mod. Knowing now to check the guides and chain really make me want to thank you and your mechanic friend. Please continue to do more videos. Stay well! -Doug

[@Ilikeryche]

How many Kilometers on this bike?

[@ShaunMurray63]

26 thousand miles so round about 40 thousand kilometers.

[@Ilikeryche]

@@ShaunMurray63 I guess that's not so bad then , for a single cylinder engine.

[@ShaunMurray63]

Yes pretty good.

[@brentmitchell9116]

So it’s not the doohickey it’s the chain and chain guides?

[@ShaunMurray63]

Yes

[@johnmitchell8925]

Why wouldn't you state how many miles on the bike

[@ShaunMurray63]

I did , it had 16.500 miles at the time.

[@XLV750RD01]

The chain is not tensioning because the OEM spring is TOO long. A fault Kawi has carried forward for the entire 30 years of production.

[@ShaunMurray63]

well yes that is a given bad design but the point im making is something has to wear on the engine to cause the need for adjustment

[@XLV750RD01]

The chain works itself into the rubber that sits on the sprockets.This reduces the circumference thus 'elongating' the chain and losening it. The spring is too long to take the slack.Take the sprockets off and inspect the rubbers and especially the springs, they like to jump ship.

[@ShaunMurray63]

good info thanks for the comments that's why we like to have other opinions

[@dannyvan5792]

kawasaki now the problem no for manny years ,but why the does notting to improuve it ???

[@connorrampage7817]

Where's the follow-up video?????

[@ShaunMurray63]

Hello Connor it's here , kzbin.info/www/bejne/iXrJk2CnbrKUpac

[@Elrod88]

What the name of those parts?

[@ShaunMurray63]

They are called chain guides in the UK.

[@Elrod88]

Another question: by coincidence would you happen to know more or less when the doohickey & guides need maintenance? I’ve been googling, YouTubing, no one seems to mention at XX miles, when a certain noise is heard or anything.

[@Elrod88]

Just asking because I already have over 9000 miles on mine and seem to recall only adjusting the chain once.

[@ShaunMurray63]

@@Elrod88 They wouldn't be any guide lines because it would be down to the mileage you do and whether the bike is maintained/serviced according to useage and possibly how hard it is used and abused. The bike would start to run roughly as the doohickey and guides start to wear , this would be a sign that it is time to do something about it. This could be hard to judge as it is caused over time and you may not notice until one day you say to yourself this bike doesn't start as good and runs nothing like it used to , that would be your indicator.

[@Elrod88]

@@ShaunMurray63 outstanding, great video, thank you much..

[@71jvf]

The videos by either Eagle Mike or Ian Schoenleber thoroughly explain the billet “doohickey” and replacing the coil spring with an Eagle Engineering torsion spring. Although I have been in more than 200 1989 to 2007 KLR’s in the past 18 years, i do not consider myself an expert. However, I am smart enough to listen to the guy that produced the first billet doohickeys in his machine shop at 22nd and Imperial in San Diego back in the late 90’s early 00’s.

[@coolkatz9012]

Plastic Chain guide looks week as piss.

[@ShaunMurray63]

And cracked.

[@XLV750RD01]

That's not an original 650C motor in there. That bike already had and engine change.It's a 650B Tengai motor.

[@ShaunMurray63]

well spotted yes I changed this engine some time ago now it is a b engine but as you will probably know the balancer set is identical to the c models im sure this setup is the same on all engines from 87 to 2007 after that I don't know I haven't worked on any after 07 thanks for your comments

[@XLV750RD01]

Not entirely. The lower left weight and the uppermost right sprocket are different. They were improved in the C, now a one piece part, that can't grenade anymore. Springs broke and fell into the engine, pins fell out and the prongs of the weight itself broke. www.imagebanana.com/s/1327/D6fHiZMm.html

[@ShaunMurray63]

yes that's true if my memory serves me well they did this mod in 1996 on engine codes around AOE 32206 but the spring chain guides doohickey ext are all there on all the engines I have mentioned the point of the video isn't about a specific year of engine but rather a range of engines with this setup and more to the point what I have found wrong with the one in the vid im just trying to say look at your guides too if you don't how will you know what condition there in more of a heads up vid not a how to or facts about individual year changes to these bikes in my follow up vid my intension is going to be has the new guides made enough diff to the setup as to make the spring work again however the spring will not be staying in the bike it will be getting the mod setup fitted thanks again for your comments

[@0fksgvn185]

Or it's from a bad tensioner AKA doohickey

[@ShaunMurray63]

Sorry for the late reply , for some reason I am not receiving notification of comments on some of my videos from youtube. Yes could be.

[@majorpay5058]

I keep looking at the KLR, and thinking "Wow, that's a really good deal." Then I watch endless videos like this, and think "Wow, that's the absolute Yugo of motorcycles..."