KLR 650 Doohickey Upgrade

Kawasaki KLR 650 Doohicky (Idle Balancer Tension Spring) upgrade on a 2009 at 6500 miles. I use special tools that make the job much easier. I got my Doohickey at Happy-Trails, made by Eagle Mike. The special tools: 1 & 1/4 inch bent wrench and 22x1.5 bolt with a small head were borrowed from friends & would've made the job much harder without the special tools.

[@BDAWGRANGER]

Thanks for taking the time to make a video, I found it a big help. I found my 08 spring to have no tension left

[@drewp9112]

i like certain aspects of the KLR but my next purchase will likely be the DR650 or XR650 largely because of the underlying issue that requires an after market fix. im not going to spend the money for a new or used KLR and feel like i have to run out spend hundreds for parts as well as tear the engine down and replace parts, ridiculous

[@VideoOverdrive]

Honda rocks!

[@scotchace8689]

What is the Torque for the Rotor Bolt? Tighten it down till it strips and back it off a quarter? Settle down folk's; just kiddin' Thanks for the info, doing the DooHickey tomorrow.

[@VideoOverdrive]

Ah, good question on the Rotor Bolt torque. I used a torque wrench, and it was hard enough I rested the 'special tool' on the front foot peg/engine guard. So I'm guessing the torque was up in that range. Sorry I'm not more specific. I'm sure I looked it up & knew at the time.

[@scotchace8689]

VideoOverdrive The proper Torque Sequence for the Rotor Bolt is crank it down to 85 ft. lbs., loosen it back up, then crank it down to 120 ft. lbs.

[@darkhorse2reign]

I just bought one. Two questions: 1) How do I know my doohickey is broken? And 2) If my doohickey is broken what do I *doo* about it? Can anyone service the doohickey?

[@WilliamCooperoverdrive]

+darkhorse2reign - the KLR does run a little rough when the idle isn't right. Several other problems can make it run rough also. So... if you're getting up in miles, it's a good idea to check it. Can anyone service it?..... there are special tools, as shown in the video. If you don't normally change oil, tires, spark plugs, coolant flush, brakes, brake flush by yourself with your eyes closed, then NO WAY is this a starter project.

[@iliaortho]

Thanks. What is the paste used on bolts?

[@davidmurphy1896]

how long does this solution last?

[@Billbobaker]

Is it really important to use permatex.. seems like it would glue the case parts together and make it very hard to remove in the future. Do you wish you would have put on the new torsion type spring?

[@WilliamCooperoverdrive]

Hi Bill. I actually had a torsion spring that was intended for this. I think the torsion spring saves a few steps of dissassembly. No reason why I chose this spring over the other. And this sealer wasn't the super-tacky type. I'm pretty sure I used silicone - based gasket sealer that hardens to a compound that is easily removed. Sorry, I don't have a tube of it close by or I would specify the model number. It was from Auto-Zone and I've used it several times, it comes apart easily and cleans up easily.

[@robertosansoni4421]

Hello, I have a KLR 2004, this model also has this kind of problem? made the change then you are quiet or you must always go to smooth and tighten the bolt?

[@WilliamCooperoverdrive]

Hi - good question. I also had a 2004 KLR and around 10,000 miles it started making a noise in that part of the engine, but I would think tappet adjustment would have been a good place to look. However, I had to move and sold it. Other you-tubers give a "before and after" sound and the engine sounds better after upgrading. It has been my understanding The Doohickey problem didn't start until the year 2007 redesign.

[@benramirez1436]

Could this possibly kill the bike and keep it from starting if its broken? My bike wont start and Im just wondering if this cause the problem

[@VideoOverdrive]

Hi Ben, I'd certainly looks elsewhere for troubleshooting starting problems.

[@Leon-ec9ge]

is it really necessary to open your motor every 500 hundred miles to adjust it ??????

[@drumstyx]

IIRC it's every 3000, and you just pop off a little rubber stopper, then loosen and tighten a bolt. Opening the engine is just to replace the adjuster with aftermarket which is known to fail.

[@jerrythecoo3295]

This is something Kawasaki should improve on...... Shaft drive would be a bonus as well. :)

[@bondo86]

Shaft drive? That would be horrible for off road use. It would make it easier to stall the engine, and probably make it easier to dump your bike.

[@jerrythecoo3295]

I disagree,..... I emailed Kawasaki & it's more of a Maintenance issue..... Easier to replace a chain than dealing with a shaft assembly. In the middle of " nowhere",..( which I agree).But they said it can be done.......

[@jerrythecoo3295]

I was just kicking the thought around,..... & it sounded nice! :). Lol!.......

[@bondo86]

Jerrythe coo lol, while their at it tell them to turbo charge it too.

[@brentmitchell9116]

I have a 2022 KLR 650 do you think I should do this?

[@VideoOverdrive]

Since a 2022 probably doesn't have enough miles on it to worry about, that's a tough call. I haven't kept up with the engineering updates for the KLR. One would hope they've redesigned it by now, a decade since the Doohickey gained attention.

[@Sam-di2xu]

it's 69in/lb

[@omari70721]

Hey VideoOverdrive. .. could you please tell me where I can buy one of those special bolt and wrench tools? Thanks bro.

[@VideoOverdrive]

+Lee Brown Eagle Mfg. Rotor Holder Wrench KAWASAKI KLR650 on Amazon Eagle also makes a Balance Idle Lever and sells upgrade springs.

[@omari70721]

OK thanks man... I knew about the idle lever.. Just didn't know that they also sold that wrench also.. Cool.

[@shreksexy6879]

+VideoOverdrive why did you decide to go with the coil spring instead of the torsion spring? Also what is torque on adjuster bolt after adjustment is done?

[@kamleshmohanlalparmar9892]

Hi, how are you?? I have the same bike as yours and I would like to have the Doohickey you changed, the new one. How may I get it please. Waiting for an answer from you. Thanks in advance - Kams

[@WilliamCooperoverdrive]

www.happy-trail.com/doohickey-klr650-all-years.html These guys have a good reputation.

[@kamleshmohanlalparmar9892]

Thank you William

[@kamleshmohanlalparmar9892]

Just one question William, is it the famous Doohickey ? Thank you

[@Sam-di2xu]

What are the torque specs for the inner and outer case bolts

[@nitroman365]

There is no specific torque specs on those bolts.

[@kennyG990]

There most certainly is a torque spec for those bolts, both inner and outer engine cover bolts are torqued to 78 INCH pounds.

[@olneymaryland77]

Holy eclectic music taste.. could hardly pay attention!

[@olneymaryland77]

seriously, WTF are you listening to??

[@nitroman365]

Thanks for the very informative video. Now go wash that nasty pig of a bike.