The DOOHICKEY killed my KLR!

Follow me on a frustrating journey fixing my KLR after the doohickey failed in my 2006 Gen 1. I had already started the doo replacement when I found it exploded in my engine, so this video is from that point forward. Thanks for watching I appreciate it.

[@justmyself1000]

That is a great looking and in great shape gen. 1 ! Glad to see you are keeping up with it! I just inherited a gen. 2 2011 and will be doing the doo in 2 days.

[@nickandmotorcycletime5246]

Thanks! It was a trusty bike indeed and treated me very well. I had to let it go due to home expenses recently. I will have one again eventually, KLR's are such a great bike. I actually started finding myself wanting a Gen 2 because of more highway riding I was doing. Enjoy yours, thats a great inheritance!

[@biggooddad]

I replaced the doohickey on my 2011 Gen II shortly after buying it used with 13K miles on it. The old one (doohickey) was intact but with a serous wear mark about half way up the spiral portion of the spring. That being said, the most concerning thing about the factory doohickey setup was the lack of tension on the old spring, it was slack and doing absolutely no good when doing the specified adjustment. The Eagle Mike torsion spring design fixed all that with a ton more adjustment room and sufficient spring tension to make use of it. I have over 35K miles on it now and no problems so far. Thanks Eagle Mike.

[@nickandmotorcycletime5246]

@@biggooddad yep! Couldn’t agree more. Although a lot of people say the bikes will run forever even with no tension on the spring. I just wanted to do it myself regardless of the debate.

[@turinhorse]

When my brother bought a KLR he said to the service guy at the dealership, i want to change the doohickey and the guy said... "oh ya, we do about 10 of those a year". its real

[@nickandmotorcycletime5246]

Agreed. Peace of mind to just change it. The bikes are pretty indestructible so they can run forever even with broken doos but not worth it to me to leave it. Ride safe!

[@adventurevin7600]

I did my Gen 1 around 10K. At 29K I had a catastrophic engine fail (Video on my channel). I have a second Gen 1 that I will be working on next week... Don't forget to maintain and adjust the tensioner every oil change

[@ORflycaster]

I'm going to look at (probably buy) a 2007 this afternoon. It only has 3K miles on it, and looks stock other than the exhaust. A doohickey, thermobob, and drain plug will all be the first order of business if I buy it. And of course, a milk crate. 😁

[@nickandmotorcycletime5246]

Nice!! I’ve been keeping my eyes peeled for one here too. I’m hoping to sell my Honda to fund another KLR. I’m on the fence with trying a second Gen this time though, we’ll see what the best deal is out there.

[@atticustheory7]

2006 as well as 38k miles. I bought the Doo and when I opened up my running bike found the spring had snapped and miraculously jammed itself during the failure. I was on the other side of this coin failure but caught it. Change your spring on older KLR650s. He is spot on, learn here.

[@nickandmotorcycletime5246]

Thanks for the words, I appreciate it. Glad you caught yours in time, although I bet these bikes would ride on without a pause haha. Great solid reliable bikes. I’m in the market for another one now, I had to let mine go because of some home expenses. I’m sure I’ll have to do the doo again to the next bike, but I’ll be better for it this time. Ride safe!

[@LTLT900]

Ive never done the doo on my 2005 gen 1. Its now got 99,500 kms on it now. Still runs great.

[@nickandmotorcycletime5246]

I don’t doubt it! It’s not completely necessary. I just wanted to for peace of mind. Ride safe!

[@motoshawn]

Yep from what I heard , you do proper maintenance and it will never break.

[@hondaryder3779]

No doohickey problems on Transalps😊 I hope she gives you no more problems. I've heard XL650V's are hard to come by in NA, Dominators and crf's not so much.

[@wranglercody8422]

I did the doo on my 2018 during it’s 600 mile break in oil change. First mod to do to a klr.

[@nickandmotorcycletime5246]

Noice! Talk about preventative maintenance haha. Well done, now it’s indestructible. Ride safe!

[@jurgenbuchelt4384]

Over the last 23 yearsI have worked on KLRs more than most Kawasaki mechanics while I looked after my bike hire fleet and after hundreds of customer bikes. I believed the Kawasaki dealers lies in the beginning and paid the price having to scrap a KL650C with less than 30000km on the clock after the idler lever broke exactly like teh one you showed in teh video and the broken bit went through the transmission ruining three gearsets and cracking the crankcase. Since 2000 I have replaced about 300 KLR 650 balancer chain idler levers. In any of the three early models up to 2007 model year it was pretty much impossible to find the OEM spring intact, even in low mileage bikes, sometimes as low as

[@bobrenk5518]

I bought the Eagle kit at the end of the riding season intending to swap it out over the winter. Sure enough, the thing broke on my last ride. 50 km ride home in first gear and a full engine disassembly. Pain in the butt but thankfully, no damage.

[@nickandmotorcycletime5246]

Whoa! That’s intense man. Good on you for sorting it out. Now your bike is genuinely indestructible.

[@slalomking]

Best access to the sump in on the left side. Remove both left side covers. Then a magnet will reach all the way to the drain plug.

[@nickandmotorcycletime5246]

I couldn’t get all the way in there unless I took the other side off also. Just wanted to be certain I skimmed every corner of the engine haha. But thank you’

[@robertwedden5761]

2015, 100k miles , clutch @ 87k , runs great , I'm 80 love my KLR

[@nickandmotorcycletime5246]

Awesome!! This is why I got one myself. I can't help but love the fact that they serve so many people so well. I had to sell mine for a home expense but last night I was talking about getting another one. Most comfortable bike I have ever owned hands down. Thanks for stopping by. Ride safe!

[@Gfthce3426]

Right on ! KLRs are such a cool trip .

[@nickandmotorcycletime5246]

Agreed, although I do find myself missing the ease of speed from 4 cylinders.

[@parcadv419]

YOU REALLY NEED TO GET THIS VIDEO TO DORK IN THE ROAD, HE INTERVIEWED A KAWASAKI MECHANIC AND THE MECHANIC STATES THAT HE HAS NEVER SEEN ONE FAIL.

[@nickandmotorcycletime5246]

I know! I was a little surprised by that to be honest. I feel like the mechanic had to say that to keep his job haha. I’m a little insecure about the quality of this video showing Dork, he’s got a huge audience. But I agree, the doo fails often, mainly in first Gens though.

[@justcallmedude]

i have the 2003 klr, now at 58,000 km, i don't think the doohickey was ever done and still runs great and i drive it hard :D

[@rustymustard7798]

The 'old guy' previous owner probably thought he was babying it, but was really lugging around all the time stressing everything.

[@nickandmotorcycletime5246]

Not a bad hypothesis.

[@rustymustard7798]

@@nickandmotorcycletime5246 I've seen that with a lot of vehicles, "old lady only drives a block to church" type thing, but the engine is all gummed up with deposits and carbon from basically idling all the time and not being used.

[@nickandmotorcycletime5246]

@@rustymustard7798 I agree!

[@jpeth7080]

Thought i would do the doo today on my 2000 KLR that I bought used I had the same similar experience as you did my spring was intact but the doo was broken just like yours i couldn't find any parts so I installed magnetic plug and hopefully it will catch any loose metal

[@nickandmotorcycletime5246]

Nice! But not nice! Yeah, after I fished around I also installed the Eagle Mike one. Have yet to find anything else, hopefully it went out with oil changes in the past. How do you like your KLR?

[@jpeth7080]

Haven't had a chance to really ride it yet. I got it at an auction it's a Marine corps motorcycle trying to restore it back to its original. As a former marine, I road the klr 250 when I was in they went to the 650 after I got out

[@nickandmotorcycletime5246]

@@jpeth7080 that is really cool! Thanks for your service man! I hope you get it going soon enough and enjoy the ride.

[@verbalwidget7267]

Did you remove the oil screen when you had the clutch cover off? I checked the oil screen on my 2007 KLR650 while fixing a leaking water pump seal and the oil screen was full of metal debris and part of the Doohickey spring. When I bought the bike, the guy said the Doohickey was done, which it was but it must have been bad when it was replaced. I just picked up another 2007 KLR with 3k miles and doing the Doo as soon as it gets here, so this engine doesn't end up like my last one.

[@nickandmotorcycletime5246]

Yeah I checked and emptied the screen. Nothing at all in it which makes me think everything must have gone out in the oil years prior. Bike ran great regardless until I checked the doo out and was concerned I had to locate some metal. Overall bike still runs great.

[@onerider808]

I’m sad the doohickey, thermo-bob, and flush-mount magnetic drain plug are required to make my (almost) brand-new bike be reliable. I’m also bummed I need to put upper guards, a skid plate, and bark busters to make my bike crash-proof (or as crash-proof as a fella can expect). Still, I love my 23 Adventure.

[@nickandmotorcycletime5246]

I hear you man! But at the same time there is some beauty to working on your own bike. Now you’ll appreciate that bike more than ever.

[@joshblack2362]

I just bought a 22 Klr is the doohickey needed? Im for sure doing the thermo bob but I havnt even hit 600 mile first oil change. I havnt heard about the magnetic drain plug though, any advice and help is welcome thank you!

[@krashgamingandoutdoors1125]

@@joshblack2362 cam chain tensioner is not needed on any of them. If your cam chain is so stretched that you run out of adjustment then you need to replace the cam chain. Don't fall for the eaglemike thing. Modding your tensioner will only prolong the problem instead of actually fixing it.

[@nickandmotorcycletime5246]

I wouldn't worry! These bikes truly are bulletproof. Its ahot debate like comments following this show. I would change it because its an easy and fun thing to do to your trusty KLR. I never did the thermobob on mine, I would just ride it for awhile and then when you decide your keeping it, modify it. I ended up selling mine because of home expenses, but now im looking for a small trail bike instead. Hope this helps.@@joshblack2362

[@nickandmotorcycletime5246]

Agreed!! Most practical economical bike I had the pleasure of owning. @@Paul_Ridgeway

[@Gfthce3426]

You know what to do next .

[@nickandmotorcycletime5246]

What should I do next?

[@alexnieto6864]

Did you ck the chain glides that keep your counter balancer chain aligned? They tend to wear the plastic part then the chain rides on the steel part and eventually pieces of steel brakes off. Also the chain for stretching or worn out chain?

[@nickandmotorcycletime5246]

Yep, after being concerned about just this I checked and everything was aligned.

[@pdp888]

Is the failed Doohickey piece Aluminum or Steel?

[@nickandmotorcycletime5246]

I actually don't know, Im assuming steel its pretty hefty.

[@paulherron4289]

If the timing chain actually fails it’s not a few hrs of digging around. it’s a trashed motor. As in very few useable parts left.

[@onerider808]

Happened on my 230,000 mile FXR, while nearing the fall Daytona Rally. (I’m from CO). I ain’t lookin to have it happen again.

[@onerider808]

Actually, it was the cam chain tensioner, and got to it before the chain shredded. It was bad enough as it was.

[@nickandmotorcycletime5246]

Right on! Hope you sorted it man!@@onerider808

[@MrPepper312]

I have the 2023 S KLR. I can't imagine Kawasaki not upgrading the doohicky on the assembly line for 2023 , but can't find any info if they did or not.

[@nickandmotorcycletime5246]

I know they built it up on the 2nd Gen bikes but some still have failed. If I had a new one I wouldn’t worry about it at all. Unless your keeping it forever and want to do it yourself, it’s super easy.

[@Schrammwow]

The Gen 3 KLRs do NOT have an upgraded doohickey. This video from Big Rock Moto with Eagle Mike shows the Gen 2 and Gen 3 parts are identical. kzbin.info/www/bejne/aILcf3dvgdpqZ9E

[@nickandmotorcycletime5246]

@@Schrammwow yeah, I’m not surprised! They will sell regardless, Kawasaki must not think it’s a huge issue (and maybe it is not? Debatable for sure). I just think it’s an easy thing to do to bulletproof your bike.

[@krashgamingandoutdoors1125]

Modifying the tensioner will only prolong the problem. If the cam chain is so stretched that you ran out of adjustment, is it the tensioners fault? No. Replace the cam chain. This is why Kawasaki does not see a problem. Because there isnt one. Chains stretch. That's that. Modifying your bike will void any warranties and in return you'll want to send it to Eagle mike since he "knows what he's talking about" it's a way for him to get business and scam folks who don't know what they're doing.

[@justmyself1000]

@@krashgamingandoutdoors1125 A cam chain shouldn't stretch that soon. Or at all to cause a problem. I've had many motorcycles in my lifetime and have never had a cam chain stretch as to cause a problem. Never had one stretch out of spec. I put over 20k miles per year on my bikes. I don't even know anyone on any other bike who has stretch a cam chain out of spec. I've heard of cam chain tensioners failing...but that's it.

[@Halcyondayse]

My doohickey has broken and I've got the stator side off. I've been able to recover all of the spring and the majority of the doohickey through that side but a small part still remains. It might have come out with an oil change but I'm considering taking off the clutch side to check the oil screen. Did you find anything in the screen?

[@nickandmotorcycletime5246]

Hey, I actually didn’t find anything in that oil screen. Seems the rest of the doo came out in previous oil changes. And honestly if it shot around in the engine for a bit it did nothing to it. Runs perfect still! I just wanted to see if anything was on the clutch side. If you want you could rinse the case out with karosene and let it evaporate after then refill with oil. But I did that and nothing came out. These things are tanks, just install the new doo and put it back together and you’ll be good.

[@Halcyondayse]

@@nickandmotorcycletime5246 Great video and thanks for the help

[@nickandmotorcycletime5246]

@@Halcyondayse haha, slowly getting a channel going. But I appreciate the words! Good luck getting it back together, ride safe!

[@nosman123]

Most Kawasaki mechanics say they replace the cylinder head before the doohickey brakes. They find that most people that have this issue dont do basic maintenance. That would have prevented this mostly not doing oil changes like they should or running the snot out of it likes a 2 stroke dirt bike

[@nickandmotorcycletime5246]

I’ve heard too many perspectives. I always take care of my bikes, and I chose to see if it had be changed in mine. So many different beliefs on this issue. But I don’t disagree with you, proper maintenance should be a priority for sure. Don’t speak up too loud or all the doo die harder will find you haha. Ride safe! Thanks for the words.

[@jurgenbuchelt4384]

Utter nonsense. Kawasaki does not admit that there is a problem because in most cases the bikes make it past warranty.

[@nosman123]

sounds like someone does not do basic maintenace @@jurgenbuchelt4384

[@barendfourie6687]

Check your guides for wear. I watch a video of a britich guy and his guides was done.

[@nickandmotorcycletime5246]

Good thinking! I watched the exact same video before I opened it up to make sure I was ready for everything haha. No wear on any of the guides which was a relief. Taking both sides off was a pain and waiting for gaskets but overall a learning experience for sure! Thanks for stopping by I appreciate it.

[@barendfourie6687]

@@nickandmotorcycletime5246 you did a good job I'm thinking about trading my dr650 for the klr 650 adventure. I like the feul injection and the highway teavel will definately be better.

[@nickandmotorcycletime5246]

@@barendfourie6687 Thanks! So far so good. My friend has a DR650, he always comments on how comfortable my seat is on the KLR. I would want a DR for trails more then my KLR, but for long adventures the KLR has been incredible. Its not a sportsbike or cruiser but it will get you everywhere you want to go.

[@CLP2102]

my gen 2 had zero spring tension at 4k miles.

[@nickandmotorcycletime5246]

Yeah… It probably would run forever like these bikes do, but I think it’s just peace of mind. Also wouldn’t we want our bikes to run as optimally as possible? My bike is way quieter since I change mine out. Ride safe man!

[@CLP2102]

@@nickandmotorcycletime5246 i installed the eagle mike doo too, it definitely was smoother and quieter now. cheap insurance

[@krashgamingandoutdoors1125]

If your cam chain is too stretched for the tensioner to do it's job then the failure didn't come from the tensioner. The failure came from not replacing the cam chain. The "doohickey" is not a problem like eagle mike wants you to think. Don't listen to me though, just a mechanic.

[@nickandmotorcycletime5246]

I appreciate the words. It was a fun and easy fix. Just would have been easier if I caught it sooner. Ride safe man!

[@leo.girardi]

It's lb/ft.

[@viralsheddingzombie5324]

I just can't get past the measly 39hp of the KLR650.

[@nickandmotorcycletime5246]

Yeah? What are you used to? It’s a total different riding experience for sure.

[@viralsheddingzombie5324]

@@nickandmotorcycletime5246 I'm used to bigger V twins. But I know the KLR650 is a great value...I'm seeing them on the used market for around $4k. Can't beat it.

[@nickandmotorcycletime5246]

@@viralsheddingzombie5324 yeah, they used to be even cheaper! But now everything has gone up. I got mine for $2700 Canadian. Not a torque monster like V Twins but they have there place. I will most likely keep my Gen 1 forever. I’m currently turning it into a supermoto for more touring and easy dirt roads.

[@TheAjc999]

Gen 1's number 1

[@nickandmotorcycletime5246]

@@TheAjc999 you know it!

[@1silvervespa]

New Plastic Razors might be safer in the Shop .....

[@nickandmotorcycletime5246]

What do you mean?