Kawasaki KLR650 Timebomb & WTF is a Doohickey?

Inside Every KLR650 There Is A Ticking Timebomb, The Balancer Shaft Tensioner!
Your Complete Doohickey/Balance Chain Tensioner Kit - bikersrun.com/collections/klr...
For The Good Stuff visit;
bikersrun.com
Receive Rod Rides & Wrenches Merch/Stickers/T-Shirts/Hoodies by becoming a Patron!
/ rodrideswrenches
Facebook & Instagram
profile.php?...
/ rodrideswrenches
00:00 KLR650 'Hello Timebomb'
01:56 Enter The Balance Shaft Chain Tensioner
02:51 FAIL #1
03:23 FAIL #2
03:53 Yeah But Not My Bike
04:20 Bring On The Solution & WTF is a Doohickey
05:41 Inspection & Disassembly
09:28 Well There's Your Problem
10:12 Fixing The KLR on a Budget
12:37 Tensioner Shaft Installation, Doh!
13:15 Balance Shaft Alignment Check
14:00 Would You Like One Spring or Two With Your Doohickey?
14:51 Drill Baby Drill!
16:00 Installation
20:38 Wrap UP!
#rodrideswrenches #KLR650 #doohickey #chaintensioner

[@TheMasonjarz]

Great video! I had a 2002 years ago and Burnaby Kawasaki installed an Eagle Mike version for me so it was great to see the process. Rod, you make the best how-to videos on KZbin!

[@RodRidesWrenches]

Thanks!

[@randyhanlon4746]

I will never do this myself, but I enjoy watching you do it so I can see all of the internals. Well done.

[@RodRidesWrenches]

If you own a KLR I am sure you can do it!

[@thodkats]

Your best video production (and content) so far! Thanks!

[@RodRidesWrenches]

Wow, thanks!

[@bogusm8940]

Wow! With all the special effects you sure are putting a lot of time into these videos. Very nice job! Not so sure I’d tackle something this big. I might just take it to you. 😅😅. Thanks again Rod!

[@RodRidesWrenches]

Thank you very much! I make videos first and foremost based on what would entertain me and to the best of my ability at the time. Fortunately the latter is improving and I apricate you noticing.

[@knottstilting]

This is seriously the most visually impressive KLR KZbin thumbnail ever, literally clicked on this video just because it was such an amazing thumbnail - only to be completely blown away when the thumbnail animated and led into the video itself!! unbelievable - and awesome 🙌 🏆 well done sir 👏

[@RodRidesWrenches]

Thanks!

[@firestorm755]

It's not dissimilar to the vtr1000 cam chain tensioner issue. In that case a thin torsion spring can snap inside the tensioner resulting in destruction. A manual tensioner in that case solves the issue totally. Honda never admitted a fault and it sounds like Kawasaki have a similar issue with the klr. It's great that parts and information is out there to solve these issues.

[@RodRidesWrenches]

Thanks for the view. This weekend I discovered a chain issue inside my VFR1200 Engine so Honda is up to their old tricks again...

[@Werkmaster666]

Good video. I have seen this fail on people that did the modification. Cause of it primarily failing is over torque as you stated in beginning of video.

[@timothymidkiff2894]

Suzuki s40 and savages had issues with the chain adjusters.

[@GlideYNRG]

Awesome video as usual mate. My old 94 DR650 Had a similar issue with the balance change tensioner needing attention every 5000km... Cough... Not sure when it was last done but it rattled like an old Lanz Bulldog. Was way out of whack and buggered the chain.. Been tempted by the KLR For some time. One day... 😁. Ahhh. Don't tell my ST.

[@RodRidesWrenches]

Thanks for sharing & the view!

[@shawkard]

Absolutely superb content . Very educational , instructional and most of all very clear. Please keep producing material . Do you have anything on 2015-2023 BMW R1250 RTLE or similar as this is the bike I’m coming back to after 17 years away from motorcycling in the UK 🇬🇧☀️😎👍

[@RodRidesWrenches]

Thanks for the kind words. Nothing yet for the BMW you mentioned but you never know what winds up in the garage next...

[@shawkard]

@@RodRidesWrenches thanks and very much look forward to future content ☀️😎👍

[@Rick081808]

That looks like alot of work

[@emmettturner9452]

“Doohickey.” Triggered? ;)

[@RodRidesWrenches]

Don't worry he said. The doohickey was done, he said. Maybe a little...

[@SMILEYRLR]

Thanks for listing part numbers.

[@RodRidesWrenches]

Happy New Year!

[@BikesnBBQ]

I have a 22’ KLR with just shy of 15K miles. Waiting currently for my supplies to arrive before I do the Valve check/Adjustment. I suppose I’ll more strongly consider doing the balancer chain tensioner/doo gadget. I plan on seeing how many miles the KLR will last or if it lasts longer than me before riding isn’t an option. 100K miles? Aloha 🍍

[@RodRidesWrenches]

There is little you can do other than pull the side case cover to inspect to see if the tensioner spring, which was broken on mine, is still intact. I do feel more secure in the idea of having the torsion spring and standard spring in place.

[@TracyTsVideos]

My only concern is adding more than one spring would/could cause the chain to tension be tighter when adjusted. Could this cause heavy wear or other issues?

[@Mikethebike-ov1yp]

WOW.

[@Mikethebike-ov1yp]

I have a 2018 KLR. Am very aware of the reported issues with the tensioner- they are everywhere on USA YT posts and there is incredible alarmist reports that if not addressed, your motor may explode with numerous examples showing this, being posted. Following purchase of my bike, i did some local research here in OZ given that it is on paper a serious issue. Very mindful of the costly replacement and the cracking of your casings- not desirable unless indicated. None, i repeat none of the long term Kawasaki specific mechanics that i have spoken with, many with 20 years plus experience with these bikes, have had to do tensioner failure repairs. Many have done the replacement at owners requests. I have chosen to take a punt and do the mandatory tensioner adjustment (rarely to never mentioned in most US posts about this issue) at suggested service intervals, rather than replace it. The bike has now done close to 70,000 kms and purrs like it did when bought- it hasn't exploded!!!. I May be lucky or............ Oz mechanics have suggested that if you are hearing undue or new noise- "bring it in".

[@user-lz2cd5kf4f]

Ola de Uruguay te veo,le pregunto lleva los 2 resortes?

[@RodRidesWrenches]

Sí, se instalaron ambos resortes.

[@user-lz2cd5kf4f]

Gracias

[@jsned2502]

Everybody relax, you will have a hard time finding someone that had the doohicky break and even harder time finding one that caused damage. Its the internet not real life.

[@elwood62]

My tensioner spring broke but the bike still ran fine. I found it in the oil filter screen when I was replacing the clutch. If I get another KLR I might do it as a winter project but not because I’m actually worried about it.

[@SRPARKER69]

Thank you for speaking in adult language. Like you, I find it childish to refer to it as a doohickey. How about making a video about turn signals? Yeah another annoying term that we all hear is “blinkers”. Drives me bat shit crazy. If you’re an adult, please speak like one.

[@RodRidesWrenches]

Well we all grow up, not all of us adults and certainly not all the time... 🙃

[@smudgemo]

The seller lied or someone lied to him. I don't even own a KLR and I know what a doohickey is.

[@RodRidesWrenches]

Thanks for the comment & view!

[@javierc2726]

The edit on this video is really horrendous

[@vintagebikes4215]

Using the plastic wire brush on a rotary tool to clean gaskets is an error...it is changing the shape of the metal, slightly. I do not expect to see unwise moves from you. Stop being lazy and start cleaning gaskets properly. An idiot working on one of my bikes did exactly as you are, damaged mint engine cases for a museum restoration doing what you are doing. In a word, "don't." The proper way to remove old gaskets is with sharpened wood, or with a razor blade in skilled hands, very little angle. Done correctly, neither damages the aluminum at all. Quick finish with 3m pad on edge. HAND WORK ONLY...NO ROTARY TOOLS.

[@RodRidesWrenches]

I understand why you say that, there is a LOT of misinformation out there. I will stick to what I know and was taught to me by technicians far better than I am. Do not confuse the bristle wheels I am using with the tight nylon Roloc discs that can round the edges of magnesium or aluminum. You can't grind an edge with a plastic brush held at a 90 degree angle to surface and as I have said, it is also far easier to screw up a gasket surface with an ill placed bladed tool than with the pneumatic you saw in the video. Happy New Year!

[@vintagebikes4215]

OK, thanks for responding.

[@MrApmech]

Total BS. If you don’t rev piss out of the motor this will never happen.

[@RodRidesWrenches]

WTF does revving the engine have to do with the balance chain tensioner? You 1 obviously did not watch the video and two you obviously don't even own a KLR so take your nonsense somewhere else. Not only is this a very well known issue, it has been documented by others multiple times over.