How to Install a Doohickey & Torsion Spring on a Kawasaki KLR650

Both generations of the Kawasaki KLR 650 have had a serious issue with the counter-balancing chain adjustment mechanism, or as most call it, a “doohickey”. Basically the doohickey tensions the counter-balancing chain and this helps neutralize engine shake and vibration, which makes for a smoother running engine.
If this mechanism goes bad it can cause engine failure. This stock mechanism has failed at varying times for many riders and it’s very unpredictable as to when or if it will happen.
Due to the unpredictability, I strongly suggest you just replace the stock mechanism on your KLR 650 with a replacement Doohickey right away, regardless of the mileage. It’s not that expensive to do and it can save you a lot of money and headaches in the future. Plus, with our tutorial video, you can do this yourself right in your own shop or garage. There’s no need to pay a mechanic to do this.
Eagle Mfg. makes a Doohickey, which replaces the weak stock piece with a stronger design. The basic kit comes with a couple of stretch springs similar looking to the stock spring and you choose a size to use. But, I’d suggest going all in and getting the additional and more robust torsion spring upgrade to the kit for a few bucks more. This is your best option and only requires you to drill a single hole with the included drill bit. Don’t worry, we show you how in this video.
*Ricochet Skid Plate Install & Review Video:
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ITEMS YOU'LL NEED FOR THIS PROJECT
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Eagle Mfg. Doohickey - Balancer Idle Lever & Spring Upgrade
bit.ly/3bfUyCf
Eagle Mfg. Doohickey Torsion Spring
bit.ly/2QEmkAj
Tusk Generator Cover Gasket
bit.ly/2Uc37s0
Tusk Generator Case Gasket
bit.ly/3adbvNA
Eagle Mfg. Rotor Holder Wrench
bit.ly/2WHX5AS
Tusk Flywheel Puller 22mm
bit.ly/2QDLuiN
Tusk 3-Piece Gasket Scraper Kit
bit.ly/2Ucorhd
Gasket Maker
amzn.to/3dkX6AC
Oil-10w-40 (2.1 quarts)
Replacement Rotor Bolt for Kawasaki KLR650 (optional)
The manual recommends a one time use. Many don't replace it and re-use the bolt.
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[@paulward9553]

Good video. The only thing you missed was making sure the torsion spring sits in the groove on top of the new doohickey.

[@lightamplifier6105]

Great video! Both content and video quality...best on the Tube. I look forward to seeing more informative videos. Thank you.

[@MarkAmazingo]

Great video. The main reason Kawasaki advises to replace the rotor bolt is because of the high amount of torque it’s under. They aren’t designed to be tightened and loosened repeatedly at those high torques. The old bolt may appear to be fine, but structurally it’s not.

[@RyanUrlacher]

good info as usual Mark. Hope you're well up there in Canada!!

[@MarkAmazingo]

Ryan, I’m surviving. Hope you guys are doing well too.

[@RyanUrlacher]

@@MarkAmazingo Surviving brother. 👍

[@levethane]

Excellent to see the reassembly part, a lot of diy sites just say 'put it all back in the order you took it off, easy'..

[@RyanUrlacher]

Thank you. We do our best to show the complete job. Ride safe & Ride Often! Check out this KZbin Channel as we have a ton of free videos for you! Check out our useful for purchase videos: www.lawabidingbiker.com/buyvideos BECOME AN ECXLUSIVE MEMBER-GET BENEFITS: www.lawabidingbiker.com/patreon Leave a flat donation: www.lawabidingbiker.com/donate Shop in the Official Law Abiding Biker Store: shop.lawabidingbiker.com Subscribe to the Law Abiding Biker Podcast: www.lawabidingbiker.com/app Join our free email club: www.lawabidingbiker.com/emailclub

[@eduardoben7106]

Excelente trabajo saludos desde Argentina 👍

[@nicktruitt5589]

Good video and explanation, now if I could get you to open the other side to do mechanical water pump seal and oil seal!

[@bigyin.7710]

I recently saw a video showing the reason for lack of adjustment was because the balance chain and guides were badly worn. To me, it's like your drive chain needs replacing but you keep moving the wheel back to take up the slack.

[@expandingknowledge8269]

I believe I just watched that video, one of two, from England I think. That bike had like 24k on the clock or something. This klr in this video seems like a gen 2 model. Either way, so much controversy over the doohickey, it stuns the mind. I think people are basically paranoid about this, look at the klr forums for evidence. If this is really an issue, how much to do the work plus parts cost? I don't have enough experience to replace these parts, or probably money, considering mechanics rates. Seems the biggest issue was with the first gen bikes, and only the springs on the gen twos. If there's slop in the chains, and the guides become worn out, probably from many miles. Then would all this worry about the newer models actually be warranted, unless they had very high mileage, and lack of maintenance, like scheduled oil and filter changes..etc. Seems like people are making a lot of money from this issue, and that in itself, might be telling.

[@bandit_ii8215]

The only thing that bothers me is you left the pin for the doohickey loose. You also left the bit in it lmao. Other than that it's a great video! Very informative. I got a KLR a couple months ago and will definitely be doing this job soon

[@BrewCityRider]

Nice work, but seems strange you guys working on foreign bikes haha! You seem to be well versed on that Kawi stuff already.

[@RyanUrlacher]

Rock on!!! Love all motorcycles. Can't get enough.😜

[@user-im7gd1jd5r]

Good video!!! Whereabouts can i buy doohickey kit? I can not do it in Russia...

[@GPz84]

I cringed when I saw steel gasket scrapers. Plastic razor blades for this guy. Nice job btw.

[@HaemonAK]

After my friend did the doo, the bike leaks oil. It's completely out of oil now. Which gasket is likely the cause of this leak, the inner or the outer? Trying to avoid ripping this all apart for nothing.

[@alexstan5358]

Doo-hickey is not the problem, it is the secondary chain guides that wear out...

[@tomg6284]

Kawasaki should be paying for this fix.

[@bobc.5698]

How many miles were on the bike at this time?

[@vibora12]

Hi! What's happen if the doohickey system broke while I roll? Im apologize for my English, I speak in Spanish! Greetings!

[@haroldyazzie3538]

Hola amigo, u be ok.. get it replaced 😊

[@rollingontrucker3719]

I have a 99 electric glide classic fuel injected it ran just fine other day and went to start it and it’s not wanting to start turns over but does not run what could this because from

[@haroldyazzie3538]

Coil

[@ryanfahrne5318]

Does the torque spring ever go bad or need replacing?

[@jacoleroux1876]

I was wondering the same thing 🤔

[@phlemdog]

Ryan used a lift. I just tipped it over in the front yard. I feel like a scrub.

[@RyanUrlacher]

LOL, worked on bikes like that for years. Too old now. I can't work like that. My knees and back would be shot.

[@eneeland]

Hello: I was interested in purchasing some of the parts. They cost $26 but the shipping was $42. Any way to change the shipping to a realistic number?

[@RyanUrlacher]

Not sure where you live etc. The shipping in our store is calculated real time by the carrier based on you shipping location. Hope that helps.

[@bayview7580]

You may want a link for the rotor bolt

[@RyanUrlacher]

Hard to find. Likely have to go direct through Kawasaki. That's what I ended up having to do

[@bayview7580]

@@RyanUrlacher TwistedThrottle sells Eagle Manufacturing about $16