KLR650 Doohickey & Torsion Spring Install (official Eagle Mike version) (incl. 2022 model)

[@EngineersHomestead]

Mechanical engineer here: that missing tooth/boss on the rotor is for a hall effect sensor to determine crank position. The sensor needs a skipped tooth or irregularly spaced tooth to determine the home position for reference.

[@microcolonel]

The alternative is an absolute encoder, but the more poles in your encoder the more expensive.

[@MSKhan-dh9id]

Now, this is how tutorial videos should be done. I don't even have this bike but it is one of the best videos on How To I have seen. Thank you for doing this.

[@BigRockMoto]

Glad it helped!

[@KiwiPokerPlayer]

@@BigRockMoto I just bought this exact bike, a used '22 Adventure and this is the first upgrade I'm going to do. I'm a car guy and have never ridden a motorbike, let alone worked on one but I'm confident I can do this myself with the help of this tutorial. Not sure if I'll get it done in an hour like Mike can though.

[@jncdi1535]

Did this on my 2012 KLR. Had a few questions along the way and Eagle Mike was there for support over the phone. Great guy and very helpful.

[@dongorsegner4607]

I’m going to be purchasing a KLR by the spring and I appreciate the video. I now look at the dohickey as a service item to do in the first year. Thanks for the great how to video.

[@kawabungah20]

This video sold me on the need for and feasibility of the counter balancer system upgrade. It is definitely something a shade tree mechanic like me can do. However, I may hire a good KLR mechanic to do it anyway. I wonder if my Kawi dealership service manager would do it for a price. I've learned on all my bikes through the years that nobody cares about my machine as much as I do.... That's why I do most of my own maintenance. Robert Pursig would be proud of me. (Zen and the Art of Motorcycle Maintenance is very true for this shade tree mechanic.) Thank you Ian for making this video... And of course Eagle Mike too!

[@drylinedrifter]

Great how-to video! I don’t even own a KLR and I was engaged. Cheers! 😎

[@chrisgreen5905]

I've never owned a KLR, but enjoyed seeing inside one, and why the doohickey is a worthy upgrade-Thanks!

[@mytkc66atbat25]

Thanks for the video to both you and Mike. I did the torsion spring replacement with Eagle Mike complete kit. Everything worked out well. Toughest part was cleaning the old gasket muck off, with out dropping it into the outside cover or engine. I used a single edge razor blade (carefully) then brake clean to soften the gasket and a small brass brush to get the last of it off. The kit did have both gaskets and I used them. It is surprising how much noise was being generated by the stock system. My bike is a 2014 with 8600 miles on it. The spring was in good shape, but not keeping tension on the chain, as described in the video.

[@BigRockMoto]

Thanks for sharing

[@anthonya8412]

Cannot thank you and Eagle Mfg Mike for this video. I bought the complete get last year when I bought my 2022 KLR and finally had time today 11/10/23 for the install. Your video made it simple for a first timer. Thank you

[@edwiltrout6685]

My 2017, 14000 miles and no doohickey change. Deer hit totaled it. Replaced with 2022 and NOT doing doohickey on it either! Where are all the people who blew up not changing it? You can spend 1000’s upgrading everything that needs upgraded and you would have an overpriced KLR. Ride and have fun. That’s what I’m doing.

[@expandingknowledge8269]

Yep not wasting my hard earned money on someone putting this upgrade in. I think it's basically paranoia that people worry so much about nothing. Change your own oil and filter, do the regular maintenance, and that's it. Love that you got 14000 miles on your bike that's awesome!!! 👍👍

[@seatime674]

Bravo...👏 ..This is all BS and have not heard 1 motor fail because of this but have heard hundreds of people with 100k+ miles on their KLR Maintenance free...Just Ride quit worrying🎉

[@christopherw4527]

@@expandingknowledge8269 14000 isn't anything to celebrate about.

[@bluefrog8670]

I spent thousands upgrading my KLR. Worth every penny.

[@bluefrog8670]

Thank you for making these parts and this video! My doohickey is now done! My bike had less than 500 miles but the spring was already slack. The new torsion spring pulls it tight.

[@JC-saves]

Thank You Ian and Mike, this video was invaluable for me in upgrading to Mike’s high quality parts. Installed the thermo Bob upgrade 1st and now the doohickey, all purchased from Eagle Mike. My 2023 KLR is GTG God Bless.

[@mark98070]

It's been so many years since riding a bike but watching your videos makes me want to ride again

[@brucecronin6396]

Great video. Great guy. Great products !! Did my doohickey in 2005 on a recently purchased '93 (A-7). Leaned the bike against the wall in my garage. 30k miles later, still running and sounding GREAT !! Thanks, Eagle Mike !!

[@richardvalitalo3670]

What a hastle for a new bike!

[@mrspeigle1]

Agreed, though you can also look at it as an opportunity. Is make note of everything you need to monkey with and make your credits according to that. It looks to me like a golden opportunity to upgrade your drain plug your shift lever and your charging system. Still I do find it absurd that Kawasaki has not fixed this issue Which has been around for decades,

[@christopherw4527]

@@mrspeigle1 Agree. They have to drill a hole and add a spring. They wouldn't have to change the casting.

[@KennethJoines-th4jk]

Hey Kawasaki. You just lost a buyer. Get off your ass. Looking at Honda Africa twin

[@christopherw4527]

@@KennethJoines-th4jk If you can find one. Wish you luck. I live in a low population state however. Could be my problem.

[@thegreenman2030]

I don’t on a KLR 650 and don’t plan to however I found this video extremely informative and well done. Going back to school at 46 for mechanic work in order to work on ATV’s and Motorcycles. Thanks!

[@jimh2061]

Great video! Thank you both for taking the time to show the world how to do this fix. It doesn't look as hard as when I first started watching this video and complaining about a new bike should need this. I'm gonna be open minded and still consider buying this bike.

[@christopherw4527]

Did you buy a Gen 3?

[@theantheron85]

Thanks for sharing! Thanks Mike for your wisdom! Watched the whole thing and enjoyed it better than the crap on TV.

[@ecalzo]

Thank you Ian and Eagle Mike for the Instructional video.. Hi from Italy ..

[@katerinap.9006]

Fantastic video. Just received the doohickey kit from Eagle Mike. Doing this modification tomorrow morning :)

[@rgfxnet]

How did it go, do you notice a difference?

[@katerinap.9006]

@@rgfxnet the job of replacing the lever and spring was very straightforward. Still took about 6 hours. I was surprised to see after 20 000 km the spring was still tensioning the chain. Now, of course, I have no idea what the true tension was prior to loosening the doohickey bolt up. I did notice my lever had rubbed a little and the spring chewed into the inner case nicely. I haven’t been able to ride it yet because of the winter tire law here. (I have the 2nd Gen KLR).

[@7MPhonemicEnglish]

I've never even heard of the KLX650 but now I know about the 'Doohickey' and the 'ThermoBob'. I think this means that I have to buy one now.

[@marty4933]

Nice video. I did this on my generation two KLR and survived. It is a pity Kawasaki didn't just buy the aftermarket doohickey and do this for the buyers. Surely they knew about the issue! That said, it wouldn't stop me buying the bike as it is such great value and so much fun. Also, is is easier to stay under the legal road speed.

[@t-bone9403]

Sure Kawasaki knew about "the issue" or what could be perseaved as an issue. If it was really an issue Kawasaki would have addressed it. Ive talked to several mechanics that service Kawasakis and not one of them have ever seen a KLR brought in with the torsion spring failure. Its just hype to promote sales of the "doohickey" spring kits and tools to install them. $$$$ the idea that your bike could blow up if this spring fails has made a lot of $$$$

[@103m95g]

Thanks for bringing us along. When I had a 2012 I got all my parts from Eagle Mike

[@brettw1518]

Done this on my 2018 KLR all eagle mike parts and she’s still running great.

[@liu3kang]

I want a KLR650 just to fix the Doohickey because of this video

[@Buckarooskiczek]

Great video! No messing around. Pro tip: spray adhesive on gasket to hold it in place. What the heck, Kawasaki? Why we still doing this???

[@bananabrooks3836]

Excellent comprehensive work.

[@josepeixoto3384]

I had 3 of those 650 KLRs in the 80s and 90s; that damm counter-balance chain was the biggest problem of that bike(besides the Ignitor, that cost 300 dollars in 1985!!! it did the same purpose as a 5 to 10 dollar part for any chinese scooter today..; what i always did to that chain tensioner was to cut the spring, and bend and re-hook the end making it shorter and of the correct tension; but eventually the damm chain becomes just too elongated,and the guides worn,that it rattles ; never changed one ,i think that the chain, guides and gaskets, plus the labour, were daunting lol

[@djamesthree]

Great tutorial, its a pleasure to watch and learn from people who know what they are about. (One small suggestion, consider putting your phone in airplane mode when you use it to film.)

[@jFlockerzi]

Did anybody else notice that Mike forgot the gasket on the stater cover? Lol thank you so much for all the knowledge, Mike! Just got a pick on ya!

[@bluefrog8670]

Haha yeah, he mentioned putting it on and then it was just magically there, they must've edited out the part where he put it on.

[@afuternik]

Very nice instructional video! That said, it seems preposterous that a 2022 year bike would have such a glaring deficiency. Also, wouldn’t such an engine modification void the warranty? If this modification is done at a shop, what would be the cost? $1000? And then there are other problems that might need to be addressed (piston rings, etc.) Taking this into consideration, it doesn’t seem like a new KLR is such a great bargain!

[@dicktrickle4197]

Excellent question

[@franciosdeaeruiu7555]

Well considering the KLR is still using the original thumper from the gen 1 in the 80s it makes sense that it is still an issue. Kawasaki has changed pretty much nothing over the 30 years this bike has been around. The only new features the 22 has over a year 1 is fuel injection and abs braking. Other than that it is essentially the same bike with different fairings. I personally see that as a good thing, it means any problem you may have has almost certainly been encountered and solved many times before. Is the doohickey an annoying thing? Maybe if you don't like working on bikes, but I enjoy taking engines of all kinds apart so personally I liked doing the job

[@clroger4]

Easy enough to do by Mike but Kawasaki just cannot move to a torsion spring during build. "Preposterous " is an understatement!! Had since 2018 to sort out the move to torsion spring and Kawasaki brings the bike back in 2022 still f'd up? Might be buying a Himalayan instead just on principle.

[@hunterhalo2]

Mike is a national treasure.

[@microcolonel]

Cool, I think I'm gonna pull the trigger and get one, and I'll do this when it makes sense to (first service?). I wonder how much it would cost them to do it at the factory. I'm gonna write them a letter, in Japanese.

[@Ghostrider-71]

Great video for newbies. Really informative tutorial. Does the torsion spring wear out eventually? I pick up my brand new 2023 KLR 650 Adventure next week! Thank you for posting.

[@jmtttk5]

Thankyou Mike and Ian. Wow what a great video. I don’t own one of these bikes yet,but I’m doing my pre purchase investigation. My only question is,why the hell doesn’t Kawasaki do this at the factory? Obviously a positive upgrade.

[@smiththers2]

and here i was thinking i was going to pay someone to do this for me. i am a mechanic, but i really didnt wanna screw it up... but thanks to this video i am no longer afraid of that!

[@davidguerin2921]

what a great video!! Really step-by-step informative

[@cans201]

Good video; not rushed and every detail covered. Did MIke use a new outer cover gasket? I didn't see one when the cover was installed. I'm guessing that new speed sensor arrangement means that recalibration is needed if gearing is changed. Can anyone confirm?

[@bluefrog8670]

From what I understand, if you go to a 16 tooth up front then the speedometer actually becomes more accurate. Dropping to a 14 would make it further off.

[@ricardofabia]

What really baffles me is the fact that this has been a known problem for decades and Kawasaki, having the chance to change the design of the dang thing on the newer KLR, did not. Disappointed is an understatement.

[@GibbAsp]

Very clear explanation. Thanks

[@nicolasartheau822]

High-tech clear simple And exhaustive explanation for a very accurate work to improve the failure of one small ordinary spring (obsolescence programmée ??). Any way a masterpiece in mechanic tutoriel.

[@BigRockMoto]

Glad it was helpful!

[@issameQ]

Great tutorial. Thank you. I am not sure if I missed it but did you put the gasket after pulsating the sealant? I didn’t see the gasket being put.

[@EEGworld]

You da man Great detailed video Sorry you got hacked I don't even ride motorcycles but I enjoy your channel

[@BigRockMoto]

I appreciate that!

[@chrisunderhill8853]

First off, Thanks BRM for the video, and taking the time. This is awesome. To Mike Thank you so much for taking your time in passing on your knowledge, and stories. Man i miss my dad heh. Its rare these days for this sort of thing. last thing i want to say, may sound weird but I want to thank Kawasaki for building the GEN 3 like they did. I totally get it. they really didn't want to take business away from Eagle Mike and that may have been a hard choice for them. If you ask me, Maybe this is not the real reason, but I think its kind of a way to give back to small businesses like Mike's. And that is awesome of Kawasaki. makes me even more of a fan of there's. God bless you guys stay safe and Ride on!

[@SilentWatcher594]

I have a 2022 and will be doing the upgrade. Thank you.

[@rollingstone3017]

Really well done demonstration. I’m almost brave enough to do this. 😂

[@michiganborn8303]

At about the 50 minute mark in the video when putting the cover back on, was there a gasket that was placed between the mating surfaces?

[@alm4132]

Yes, he didn't show it but it's there.

[@michiganborn8303]

@alm4132 👍 Thanks

[@RicardoDecca]

Great video, but when was the outside gasket put in place?

[@flipfpv4539]

Great video and info but also a bit of a worry I’m getting a new Gen3 KLR 2023 in 3 weeks time I’m a newbie 😊 So the more I look on KZbin the more I stress lol…. Just to confirm with a new bike 2023 do I only need to change the torsion spring if I do it before 5000miles… I’m in Australia and can’t find anyone to do it now I’m worried 😟 Thanks for your help

[@johnhamilton2680]

Eagle Mike ROCKS!!!

[@64faffi]

Thanks for posting this. Unless I managed to miss it, the video did not show or mention to fit the gasket for the outer cover during reassembly, which is the only thing not covered that I could find.

[@djsi38t]

No gasket needed for the outer cover.

[@Don2006]

@@djsi38t I don't see why not. The bike comes with a gasket there, and Eagle Mike includes it in his Doo set.

[@edwardl.990]

Hello, great video but instead of a torsion spring why wouldn’t you just use a shorter spring where the stock one goes and increase the amount it can adjust??

[@chrushernator]

Makes sense, except it can only pull so far in a straight line. The torsion spring should be able to pull it further because it can continue around the whole loopdeloop

[@TheSocialliberal]

It's awesome to see The Eagle Mike install a doohicky replacement. Also I was wondering if you could tell me which Bosch impact drills he was using, I need those in my life for my africa twin.

[@spacetruckin6555]

I guess I'll stick with my DRZ, thank you.

[@danledbetter9535]

very good video, just curious, how much will this upgrade cost to have done by Eagle mike?

[@slalomking]

Ian, thanks this video was fantastic

[@obfuscator]

Good job. And great way (good habits) working on the machinery. Please send this to Kawasaki.

[@akonitony2]

I started expressing my KLR's torque output in inch-pounds. Impresses all the ladies ....

[@richardvalitalo3670]

Hey!, didn't see a gasket for outer cover Mike/Ian.

[@brentmitchell9116]

I also didn’t see one.

[@wholoveskjs]

IAN--enjoy your videos. Really thinking about KLR650 vs. AT vs. T7. If I get a new bike, likely will get the KLR. How much does Eagle Mike charge for parts and labor? TIA.--Simba

[@jptrainor]

What's the root cause of the loss of tension and why does nobody address that? It seems, from what I've read, that it's caused by wear of the rubber bushing on the idler sproket. Nobody seems to change that. If it's a wear part, why not change it?

[@MrPepper312]

I have the 2023 KLR 650 with 1300 miles and the engine a has noticeable engine tick so took it to my dealer and they said they disembled the motor to look at the spring and tensioner and it only took them about 20 min total and had it back together. Bull S..t. I know it would take longer that that. So I still have a loud tick and they said some bikes are louder than others. I have had a least 15 bikes over the last 45 years and this is my third KLR, so I know when something is not right. So will have to find a shop I can trust that can do this mod.

[@ejutley]

I've been considering buying a XLR and still planning on it. This was an awesome video that even gives me more confidence that it's the right bike. It's good to know there are mechanics that have been there from the beginning. Are the upgrade parts available for purchase for DIYers?

[@ejutley]

Disregard my last question, I checked the description for the links. Again, awesome video!

[@clroger4]

I am also in the market for a KLR and the talk of the Doohicky was stopping me. Now I am back looking for one thanks to all.

[@515klrkillahoobie6]

Torque to yield stator bolt good to know ordering fresh now

[@JoshHefnerX]

Any remedies for a leaky doo hole besides pulling it all apart again and replacing the o-ring? And what's the part number for the stopper?

[@stringtwister7654]

Mike is the salt of the earth! He knows more about a klr than the engineers who designed it! People says the doo isn't a problem don't have eye's! Hell just look around the gen 1 would break into pieces and kawa re designed it, if there isn't a problem why did kawa do that??? The gen 2 and 3 loose spring tension. All the youtube videos and pictures on forums can't be fake. We did our 2 bikes before 5k. I currently have 22k, and the engine is quiet. It sounds like it did when new. Oh, i also have a thermobob.😂

[@sanatandharma4435]

Please forgive my lack of knowledge here! Why tighten that doohickey bolt? As the spring take up the slack from the chain, does it not need to allow the spring to do it's job? Or, once tensioned do you tighten the nut and lock that spring into place. But would that not stop the spring from allowing tension to be kept as the chain stretches? Sorry!! I am a little confused!

[@clivegreenall309]

The locking bolt must be released occasionally (after a few thousand kms) so that the torsion spring can re-tension the balancer chain...Then re tighten the locking bolt. Not sure how often this must done..maybe check your manual for recommendations. Rgds from S Africa

[@jasonmoran9099]

Great video, the only part that made me cringe was not starting bolts by hand.

[@ChiTownTino]

Well done!

[@vegasranger]

Spoke with a Kawa mechanic and he has never seen the factory doohickey spring or tensioner go bad. He said with regular maintenance you ca change the spring when you change the timing chain.

[@Toofer69]

So if somebody buys a new KLR650 and they want this corrected before problems arise, roughly how much is it going to cost to have someone fix it?

[@davidgriego8722]

Great video 👍🏻

[@psyghtseer]

doing mine right now. i was worried it had already been done and im wasting my time. NOPE! the stock was broken and LOOSE in the engine!! its a wonder it didnt grenade itself! holy shit

[@celtics9348]

Cool video, Kawasaki still hasn't fixed this for decades that is a deal breaker for me. Buying a new bike and having to do this to it? No way that is complete B.S.

[@slalomking]

Yes but, it is the bike !!!

[@LTVoyager]

The video was almost an hour, but there were clearly several breaks to clean gaskets off cases and such. What was the real elapsed time for this work?

[@AdventureTomek]

Man, I really need to do this on my 2009 KLR

[@brentmitchell9116]

I just purchased a 2022 KLR 650. I have the four year extended Kawasaki engine warranty. Every time I ride the motorcycle I feel like my doohickey will let go and my whole engine will explode. Should I fix this or just continue to run it?

[@tieoneon1614]

Just ride it. Most people never change them

[@brentmitchell9116]

Thank you that’s what I’m going to do. If I start hearing weird noise or if I’m up around 15-20k miles I may look into swapping it out.

[@expandingknowledge8269]

All your worry, from the power of suggestion of people promoting fear!

[@katherinemcdowell45]

Too true. This is an excellent portal that shows the power of persuasion and how very very gullible folks have become. Have spoken to many long term Kawi mechanics who deny ever having had to repair a destroyed KLR motor due to doohickkey.

[@MB-qo6cq]

Ok so you have to modify this bike to make it rideable?

[@Steve-yu6pq]

its more like you should replace it so it lasts forever

[@LTVoyager]

Nothing to do with being rideable. This is a longevity modification.

[@dring83]

Do you have a link for that ratchet? please!!

[@jonr3891]

Nice. Eagle Mike = badass. Re: torque wrenches, do you have any thoughts on Tekton tools? I recently bought both 3/8, and 1/2” torque wrenches from them for moto work. I’m a fan of their stuff. ??

[@stephenwatson2328]

What brand is the Ratcheting Handle Ratchet? Can't find one on ebay

[@AzEagleEye]

I would like to know as well. The brand on the handle was never still or in focus enough to see.

[@alm4132]

@@AzEagleEye It's a Blue Point. Snap-on. Bring lots o'money.

[@DrTarentaal]

I've got a 2022 KLR 650. Absolutely love it. But I'm not touching the engine until warrantee runs out. Even then, it is unthinkable that the 2022 engine still has the same issues. I'll be the test case to see if it can do 100000 miles without this mod.

[@Hansengineering]

Well if you're trying to reach 100k miles without opening the engine you won't. The valves need adjustment about every 7500 miles.

[@clroger4]

How much does the valve adjustment cost? For me that would be every other riding season. I would have tires and valve adjustment at every 7500.

[@shimy333]

...doohickey... thermo-bob..and watch the dingleberry... ok got it...

[@mikethomsen5096]

Do all dealerships offer installing this upgrade….

[@mountainlife1165]

What is the average labor cost (if there is such a thing) for the installation of this doohickey? I just bought a leftover 2023 Adventure ABS. Thanks

[@alm4132]

Should be 1.5 hrs for a competent mechanic.

[@rockinghamlab634]

Can you make a video of sounds of dohicky going bad? Thanks.

[@jacoleroux1876]

Does the torsion spring fail or need to be replaced after some time?🤔

[@alm4132]

Don't see why.... clock springs (which is what he's using, don't know why he calls it a torsion spring) have a very tolerant range as well as low fatigue rate.

[@hellraisingvtec]

Great video, thanks

[@BigRockMoto]

Glad you liked it!

[@timtarbet7301]

Great video... at 28:45 you made me look at my phone....LOL

[@74ventura11]

is there a more in-depth slower longer version

[@alm4132]

Play it 1/2speed.....

[@ogdadbod]

Where is his shop? Sure wish I had someone close by me

[@postersm7141]

I don’t even own a KLR but had to watch the video because it was so well done and I knew of the issue with the KLR and I was curious. I do on a 2021 Kawasaki Z 900 RS café and I love it. I’ve owned over 30 Kawasaki‘s in my lifetime and hopefully my new Z900RS won’t have any of these deficiencies. I’ve mostly owned KZ Street bikes in the past and they’ve always been bulletproof. It seems that KLR is also bulletproof with the exception of this manufacturing defect. Shame on Kawasaki for this one

[@Joe.M]

Are dealers aware of this problem? Can they do the upgrade or is this something bike owners are doing themselves?

[@natvega1]

I wonder when that little hole starts to stretch what are people going to invent next, the spring makes an indent on the case, maybe a little aluminum weld rod untul Kwasaki can computerize a better long lasting fix and an inexpensive fix.

[@Davran2742]

Thanks for this.

[@brantmcfarland517]

Good job guys.

[@Wabbit1961]

I'm a noob so this might be a stupid question, but why not just replace that spring with a shorter spring that has the same tensile strength and stretch it into place? That stock spring looked like it was totally loose.. On another note... What factory mechanic would do this mod for me since I'm not mechanically inclined? Do they know about this mod and where do I get that spring you use? If I plan to put miles on my bike as a commuter, say 12,000 to 15,000 miles a year, is there a maintenance schedule to deal with this issue? Btw, what's the valve adjustment interval one the 2022 model?

[@matthewkhieokham3152]

Looks like there is two adjustment lever on the 2022 model do we just keep the inner lever attached to nothing?

[@Rrrakanishu]

Could opening the case and doing this upgrade void factory warranty?

[@chrushernator]

Pretty sure it would 😂

[@Rrrakanishu]

@@chrushernator I contacted the dealer where I purchased the bike (new) and they said “maintenance on your motorcycle is your responsibility unless you reach the valves, that of which would void warranty, also I would need to complete a checklist upon every preventive maintenance service for the first 12 months”. This was yesterday after I posted this comment. Also, I have a 5 year warranty through my financial institution.

[@chrushernator]

@@Rrrakanishu just the values void it?! Awesome 🙌 Are you gonna go for the mod? Either way, enjoy the bike, they look like a blast, ride an extra mile for me

[@Rrrakanishu]

@@chrushernator yes, because I don’t want to run it with the stock parts just to be safe.

[@kong3]

Where? What shop is this. Id like to take my 22 there for the doohickey. Thx