The Doohickey Will Destroy Your 3rd Gen KLR !!!!! 22 Klr Build Series

Part four of the 2022 KLR 650 build
get your 2022 klr 650 parts @3D Cycle Parts
www.3dcycleparts.com/
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[@GaryKLR]

Rode my Gen 1 for 10 years, rode my Gen 2 for the following 10 years, combined around 90 thousand miles, plan on riding my new Gen 3 for the next ten years. No Doo's or Bob's on any of them just great riding fun!

[@FullThrottleJunkie]

I am constantly pushing the bike to its limits so anything i can change to help the bike last I do it

[@StacyHagerty]

Gary Rodgers👍😎

[@unclebadger597]

I'm on my second one. Never had a problem.

[@sboy1955]

There a lot of folks in the same mindset..

[@Actias1974]

The KLRs don’t need all this stuff. It sure makes for an active parts sales segment though

[@tieoneon1614]

I have yet to ever hear of the doohicky ever wrecking a KLR, from anyone who actually owned a KLR. Me included @ 36k miles on a Gen 2. You hear it from people on forums, and people who are worried about it and change it. To me it seems like the Great Toilet Paper shortage of 2020...where people hear about it, panic then do it. I wont be changing the doohicky or thermobob when I get my Gen 3 either

[@FullThrottleJunkie]

I have personally seen what can happen it its not changed. just my opinion i think its a bad design from kawasaki

[@tieoneon1614]

I wont knock anybody for changing one. However I think titles like this, and other people saying this bike will self-implode off the showroom floor is nonsense. If Kawi knew about it and hasnt done anything about it, to me that says how little of an issue it is.

[@larrytucker1945]

No. I know of only a sample of three old KLRs but they each have over 36k. All Gen 2s. Then highest mileage bike has replaced the doohickey spring twice and also the balancer chain. That owner is an old Suzuki dealership owner from the 70s-80s. He believes the doohickey mod is a smart bandaid for the chain stretching.

[@francof1635]

@@larrytucker1945 "He believes the doohickey mod is a smart band aid for the chain stretching". When you run out of adjustment. Its time to replace the balancer chain. If the chain stretches to much. It will start to cut into the boss at the bottom of the engine case and also wear out your chain guides.

[@StacyHagerty]

Tie One On 👍😎

[@crockett11000]

Sorry Kiddo, #1 it's a Balancer chain, Not a Cam timming chain as you called it!. #2 what you call spring wear on the case spring post is put there on purpose.. A grove in the post is there to retain the spring from slipping and flying off the post!. This same grove is done in multiple spring applications, Even in Firearms! So it is Not wear!.. For the 2022 KLR the spring was also changed, with a longer pull range. Take it from a guy who has 2 aero space degrees, a now retired Kawasaki mech/wrech since 1977, and owning 2 each gen 2s and a new 2022 adv abs KLRs... It's funny everyone talks about the doohicky, but nobody says anything about checking the valve shims!....

[@gregspace2]

I am so glad to hear this I just bought a new gen 3 2023 KLR650 and my kawasaki dealer says they fixed this issue, so I believe a kawasaki mechanic and dealer first, I bought my first motorcycle a 75 KS 125 from this same dealer 43 years ago

[@sirjamesdouglas2503]

2 thumbs up

[@Tatsunami_Studios]

Did you remove your doohickey? I really don’t want to get that deep into the bike. Do you think it’s necessary?

[@poweredbyrice5708]

@@gregspace2 They did fix it. The first Gen had a 2-piece design that could fail, the Gen 2 fixed that, on the Gen3 they fixed the remaining and most important issue that is the Cam chain Guide...they beefed it up a lot. An old man comes along starts a bunch of hysteria, gives it a stupid name and boom gets sales because he also sales the "solution" lol. People will fall for anything

[@ecopeland1321]

So many thousands of miles on KLRs over the years between me and my friends. None of us have done the doo and none of us have put tin foil on our windows. So far no engine damage and none of us have been abducted by aliens.

[@FullThrottleJunkie]

i want to be abducted by aliens

[@bobsullivan5714]

@@FullThrottleJunkie I rode my KLR for 10 years. Did anyone ever call me KLR Bob? Nope. I drink a gallon of coffee a day. Did anyone ever call me Coffee Bob? Nope. But....Get probed just once.....!

[@katherinemcdowell45]

Too true. Lot's of alarmist hype such as this post. Some folks are getting wealthy off this. I own 2018 KLR with 50,000 kms without the "Doo" having been done. Have spoken with many Kawasaki specialist mechanics, some with decades of experience. NONE have said they have had to repair "Doo issues" Maybe we are all lucky. Rationales explained are good but "necessary" replacement is questionable. Mechanics have suggested if it starts making a noise "bring it in"- it hasn't and i haven't had too. The KLR purrs just as well as the day it was bought. PS make sure you do Doohickey adjustment at service intervals.

[@mayimbe2198]

I hate click baits so I unsubscribed. This video is not about the Doo hickey not working, this just another video of you doing an installation and promoting the doo hickey, nothing new to hear or watch here.

[@FullThrottleJunkie]

Just my opinion 😁

[@doublex632]

First, this is a great video, good job explaining things. second, how do we really know if Kawasaki didn't harden that notch a little more and or strengthen the spring. I really don't think Kawasaki would come out with that info, as it's an internal RD thing. I think I purposely bought my 22 Traveler not to do the Doo or thermabob, so we shall see. If I get stranded in Idaho, I'll let you know. Peace out

[@paulcondie2520]

I have a gen2. Read all the hype and after 30,000 miles I pulled mine apart to check valve lash. So figured I'd check the DOO?? Lol. Mine was just about of adjustment but after 30,000 miles don't think the chain would of stretched anymore. I've never actually seen any proof of doo destroying an engine ever!!! Alot of talk, but never a picture or any proof that the door was the cause! I know eagle Mike got rich off of the interwebs haunted klr story!!! Also my valves were in spec!

[@FullThrottleJunkie]

The doohickey doesn't have anything to do with the valves. It is the tensioner for the counterbalance shaft. The doohickey on the first generation would snap where the adjustment bolt was. Kawasaki fixed that issue with the adjuster itself. The problem that is still persistent is the spring. The spring will rub on the housing and fail. The spring is a bad design. I have personally seen several klr650s with issues from the spring. Everything from the spring not having enough tension on the tensioner. To complete failure of the spring and falling into the engine case. Eagle Mike's kit doesn't only replace the doohickey but it also replaces the spring as well to a completely different spring that will hold tension on the doohickey.

[@paulcondie2520]

@@FullThrottleJunkie I know that! Since I already tore apart to check the valves I went ahead and checked the doo. On gen2 you gotta take alot apart to do anything so since all plastics off I decided to do both. Ask a Kawasaki mechanic how many failures he's seen? I've researched the doo alot asked old Mechanic's, most never new it was a thing!

[@omgitstiger]

I,ve also have asked numerous long term Kawasaki mechanics and similarly they all deny having had to do Doohickey repairs. Not saying that it isn,t a potential problem but clearly not as much as is claimed on line such as in this post. My 2018 gen 2 has 60000 klms on it and surprise, surprise the motor still purrs like the day i bought it. Like a previous post stated "you,ve wasted your time and money"

[@paulcondie2520]

@@omgitstiger yep, I've asked many myself with the same reply! Lol

[@timlubbers2884]

@@paulcondie2520and yet my 17’ (with 18,500 miles) had no spring travel left, so any future adjustment would do nothing for keeping the chain properly tensioned. The spring was fine, attached and no noticeable wear, just no more adjustability in the future. Considering I had over 175,000 miles on my last bike (a bmw) the lack of ability to properly tension the chain would have caused problems, not sure what problems but I didn’t/don’t want to find out … 🙏🏻🙏🏻

[@ChrisBakerElToro]

First of all, great video👍🏻 Secondly I’d just like to say that my Gen 2 has 52K miles on the original Doo. So… I suppose it doesn’t hurt to change it but I’m in the mindset that it’s mostly internet hype. Same with oil burning. My bike doesn’t use or burn oil excessively. IDK 🤷🏻‍♂️ to each their own

[@FullThrottleJunkie]

Right on!

[@nathan00campbell]

I agree with you about to do hickey, but I'm honestly impressed and would love to see with my own two eyes a Kawasaki that does not consume oil. Every single Kawasaki product I have ever owned, has Mystery Oil loss from new. I'm still in the first 300 miles on my 2023 KLR 650 so that is yet to be determined on this one

[@nathan00campbell]

At 17:22 it doesn't really look like that spring will be retained properly as it hooks into the doohickey. It looks like under vibration and use it could easily jump off. Also that rotary style spring is not going to have the same spring tension that the original spring did. It's not going to be near as strong. Honestly the revised system looks more sketchy than the original system.

[@Turco949]

13:30 - How certain are you that the groove wasn't done at the factory to prevent it from moving and slipping out?

[@MrJmattr3]

Doing mine at 1000 miles! I love my m12 Milwaukee ratchet! I use it daily at work! Just don’t understand why people want to believe this is not an issue!

[@billbonu1639]

Yeah man as soon as I got home with mine I disassembled it down to the crankshaft then put it all back together again.just to be safe.

[@espacef1fan]

The spring doesn’t wear out or anything. The chain guides and chain wear and need inspected periodically/replaced as needed. The doohickey mod just bandaids the problem

[@FullThrottleJunkie]

I'm getting my hands on a 3rd gen with 17,000 something miles. I'm going to be checking the valves as well as installing the Doohickey for them video coming soon

[@timlubbers2884]

@@FullThrottleJunkieif you pull the covers to check on the the balancer system, pay close attention to the the lower left weighted gear. It’s the primary culprit for the doo running out of tensioning ability. I believe in the replacement of the doo spring, but alot of the spring not having/maintaining tension issues are because that gears rubber material breaks apart … 🙏🏻

[@rameylewis7730]

Thank you for making the video. It's good to see how to change it out.

[@FullThrottleJunkie]

There's a better install video out there from Eagle Mike

[@FullThrottleJunkie]

This is just how I did it

[@edwiltrout6685]

I changed my tires, they might wear out.

[@FullThrottleJunkie]

Better be safe than sorry 😂🤣

[@Actias1974]

Ed’s comment wins the comment section.

[@RemboUSMC]

Oh......the sound of that washer......OUCH! Glad you were able to get it out.

[@FullThrottleJunkie]

It happens just glad I was able to get it out easily without having to take apart the engine

[@g-moneyrides8341]

Interesting piece. Didn't know anything about it till I watched it.

[@FullThrottleJunkie]

Yeah if kawasaki would just fix the spring 🙄

[@MrJmattr3]

Great guy! Have personally talk to him when my Gen 1 doo fragmented. He told me where to go searching for the pieces! Clutch side bottom under the trans!

[@MVelocette]

Actually, no … 6 KLRs over the course of 30 years, never a doohickey issue. A few bad ones, then every reviewer has to echo a very small issue. So you really think if it was a big issue, Kawasaki would just ignore it?

[@FullThrottleJunkie]

Kawasaki hasn't ignored it they have revised it several times they made the doohickey itself thicker from the first gen to the second gen. but me personally just think it's still a bad design

[@thenoob4280]

I had exactly the problem of the spring wearing into the case mount. No tension at all… So it was a big problem.

[@BrunoB99]

My gen 2 had no tension on the spring at 20k km. If you don't look you might never know and might never have any major problems, just a slack chain. It was a good fix for my bike.

[@kong3]

Other vids warned about the spring. They captured it wit a magnet against it and caught it as it came loose. A good curved needle noose would have helped. glad you got it.

[@FullThrottleJunkie]

Yeah it had me worried

[@johnmitchell8925]

I had to replace a broken cam tensioner spring on a 2003 klr 650 I bought brand new changed the oil every 1k miles and ajust ed the cam chain tensioner per severe recommendation. It started rattling under warranty had about 9 or 10k miles on it dealer said they couldn't hear any noises anyway it got a lot worse so I popped the side cover off and the tensioner spring was just hanging broke in half. So I just went and bought a new spring installed it and road the bike another year with no more issues till I sold it for a dr 650

[@OTRinadaycab6207]

So would you recommend having it done prior to delivery of the bike? I’m purchasing my ‘23 before the end of sept. (To get that grand rebate!)

[@antoniorios3856]

I added the thermo bob and I did notice improved idle and consistent throttle response after. But will your bike seize up if u don't get it? no probably not, especially if you stay on top of maintenance

[@FullThrottleJunkie]

I plan on keeping this bike for a long time and I beat the hell out of it. So any little thing I can do to prolong the life of the bike I will do it

[@dieseltu1035]

Yhermobob runs to hot at 195. If it was 180 I would do it . 195 will cook the gaskets

[@antoniorios3856]

@@dieseltu1035 different thermostats available

[@emilbart3690]

Thank you for the video. Would you suggest waiting to replace it until after the expiration of warranty or is it an immediate need?

[@FullThrottleJunkie]

If you plan on using the warranty I would wait until the warranty is up to do it because if anything fails the dealer would give you a new engine theoretically

[@PP-wz7mp]

Just forget this bullshit.... Never trust a man with that hairstyle...

[@MrGenerichead]

Great video

[@FullThrottleJunkie]

Thanks

[@lunarluna]

LOL, I did the same thing with washer falling into engine case. That was a bit stressful.

[@FullThrottleJunkie]

Luckily the magnet pulled it right out for me

[@lunarluna]

@@FullThrottleJunkie yea same here. I did find the engine now runs a bit smoother with increased tension on the doohickky.

[@donkimes2135]

It’s a shame Kawaski didn’t fix the doo-hickey and upgrade the piston design for using oil but they didn’t.

[@FullThrottleJunkie]

If they've changed all of that I don't think the bike would be sub 10k usd

[@TEXASTR0NG]

It’s all part of the fun of the bike in my opinion.

[@shugyoforyou211]

You've got the right attitude! 👍

[@shugyoforyou211]

Needs after market pegs, shift pedal, hand guards and a "thermo-bob" but they're all pretty minor relatively inexpensive mods. Pros far outweigh the cons

[@eminiscalperpro9729]

never had any oil usage problems on my gen 3. Plus a lot of the oil issue was from people running excessively high rpm's, which the KLR is not designed for and probably had poor maintenance. I think the gen 1's and early gen 2's were the main ones to burn excessive oil, but so what if they burn a little oil, look at some of you 80k+ bmw's, they burn a qt per 800 miles, the toyota scion tc's burned 1qt per 800 miles also, new from the factory. People harp too much on a great motorcycle that can be bought new for 6-7k in some places

[@rg5445]

If you have a KLR just change the Doohickey but it’s not because you must, it’s because it’s fun to do and you learn about your bike. Plus the Eagle Mike’s replacement is way better so it’s definitely an upgrade.

[@FullThrottleJunkie]

100%

[@sirjamesdouglas2503]

I disagree. As an engineer I can see several faults with his design. One, you just voided your warranty. Two: the spring rubs on an edge. Three: it pulls unevenly. Four: it can come off. Four: it adds more adjustment to the tensioner, allowing the chain to be adjusted to rhe point it is actually causing damage. Fifth: you cannot inspect it without a complete breakdown. What are the specks on the spring? If mine does fail, I have a warranty for that. I ask if it is so prone too catastrophic failure and as soon as some claim, I would think Kawasaki would have got tired of paying for the repairs. And some lawyer would have started a class action lawsuit for all the failure out of factory warranty. There is such a thing as implied warranty.

[@expandingknowledge8269]

I truly understand your views on the doohickey. It seems you ride a lot, and put some miles on for sure. This might be a good mod for the klr, but really seems based on fear of what will happen, instead of what might happen. Keep up on the maintenance and you should be golden. At least you have addressed your fears of the unknown.

[@FullThrottleJunkie]

Totally agree

[@kareemebanks3785]

How long does the doohickey mod last for, or is it a permanent fix?

[@natvega1]

Seems to me like everyone is trying to get the most out of that chain which probrobly only has a lifespan of about 8,000 miles and maybe more if you ignore the noise and drive slow. I think the chain is about $200 and the guilds another $85.

[@sirjamesdouglas2503]

Where did you come up with that number

[@Actias1974]

If you are paying 200 bucks for a chain I have a bridge I’d like to sell you.

[@markmc9229]

The myth lives on …

[@FullThrottleJunkie]

🤣🤣🤣

[@josephgeorgeejr7039]

If I were to replace a doodoo I would certainly not do it on new bike, maybe at like 25k miles..also most folks who kno the actual name of the doodoo..they definitely don't usually ever say to replace it, good luck anyhow! I bet money that is as far as that metal would ever wear down, no way that's wearing through in my opinion, maybe after like 15-20k

[@grim_adventures]

Ok but what if I don’t have a drill press? And just a normal drill

[@FullThrottleJunkie]

yeah you will be fine

[@scottzeitler37]

4/18/2023 Please explain the drilled pin hole.

[@FullThrottleJunkie]

The hole is for the spring, it holds the spring

[@billbonu1639]

Gee should I hang a little bell under it too?

[@FullThrottleJunkie]

Or a big pair of truck nuts

[@eddie5270]

Like the keychain idea!👌😉

[@PaulWegner1]

Wrong! The Doohickey spring won't wear out the post it's attached to. Why? Because when the Doohickey is clamped into position the spring does nothing. The only time the spring does something is when you loosen the Doohickey clamp bolt which allows the spring to exert tension on the Doohickey which in turn tensions the counter balancer chain. And yes, the use of an extension spring in this design is a poor choice and shows that Kawasaki doesn't know any better or doesn't care. The torsion spring is superior.

[@FullThrottleJunkie]

I have seen the post have some damage on a 2013

[@XLV750RD01]

@PaulWegner1 You haven't understand the system. You spread false information.

[@MrPepper312]

NEWS FLASH. My 2023 KLR dohicky failed at 1884 miles. Also I have the STEERING WHEEL WOBBLE due to bad bearings from the factory. Thanks Kawasaki

[@asherlito3801]

Wait so they put all the work to update the bike and didn't even get this fixed.

[@FullThrottleJunkie]

They changed up a lot but the spring is just a bad design

[@MCHoodlum13]

This video is for the doohickey cult.

[@FullThrottleJunkie]

Pass me my tinfoil hat

[@poweredbyrice5708]

That crappy little spring is a "solution" lmao

[@kornbred1653]

I just put a deposit on this bike and I'm already thinking I made a mistake! You're telling me that I need to replace $200 worth of parts and own $200+ worth of tools to replace an internal component on a 2022 bike?

[@FullThrottleJunkie]

there are plenty of people who never change a thing on the bike and its just fine it comes down to preference i ride the bike really hard and i want it to last as long as it can so if something helps the longevity I'm going to change it

[@texashillcountryadv9197]

Bro ur good it’s hype to sell some shit u don’t need read the rest of the comments from people that have actually put miles on these bikes

[@alanhall3297]

Starter gear hits spring with no runout on gear. I would NEVER put this shirt hole part in any 2nd or 3rd Gen bike

[@zerobucks9]

wanted to watch.....auto focus is enough to make you car sick. I would turn that function off in future vids.

[@FullThrottleJunkie]

Lol it's a work in progress

[@unclebadger597]

Just leave it alone and ride the crap out of it

[@FullThrottleJunkie]

I don't trust the spring

[@texashillcountryadv9197]

My kawi tech who’s been one 20 years longer then I’ve been alive and seen thousands of klrs and serviced many through there whole life says he never seen one fail when proper factory recommended maintenance is done as well as having the tension checked a few times throughout its life like 30k and 60k… so don’t trip eagle mike just has a great marketing strategy and he looks so honest but how can he be the expert as many like to say he is when he is the one profiting off of the sales of the mod so of course he goin cut some up with a grinder or bend them in a vice then show u then and say they came out a real motor but never seen that in any video besides his so make ur own decisions on it but I’m just sayin.

[@FullThrottleJunkie]

The doohickey itself was a problem in the first gen but the spring is a continuous problem that's all I'm saying

[@XLV750RD01]

The Kawi mechs are lying.

[@pasdutout4690]

I can't see how this spring can wear through that much aluminium , in say 50K miles , Show us one such case. Broken springs from lever breakdown , yes, but not this degree of pin wear. What usually happens is that as the chain slowly stretches (normal wear) , the whole setup starts vibrating worse & worse , only to break the then stressed out adjuster lever (first gen welded ones were rather weak , and too loose -fitting on the excentric idler shaft. Later oem levers are one-piece , more solid ....but still vulnerable to excessive chain vibrations from sdjustment neglect. Not a brilliant design anyways , as the $300 CAN chain is known to stretch rather quickly , probably due to insufficient tooth contact with the crank sprocket. My friend's KLR shows no doo- associated wear at 10 K , but was adjusted twice (very easy, just loosen/tighten the adjuster bolt ), and he rides it like grandma . Oh , he has the doo done , with the coil spring (with no wear on the Al mounting pin). Me, I 'd stay away from this complicated , flawed 'design' . Just too many weak spots. In fact , none of today's dual purpose bikes ipleases me , except the XT 250 (this thing IS reliable, period

[@chadkline4268]

I disagree. Generally, it is the chain guides that wear, not a broken doohickey problem. SEE: kzbin.info/www/bejne/jmOZh52plL-pnKM

[@FullThrottleJunkie]

Technically it's not to doohickey that is the problem it is the spring

[@chadkline4268]

@@FullThrottleJunkie the spring only appears to have no tension because the chain guides are worn out.

[@FullThrottleJunkie]

The spring rubbing on the housing falling apart and then falling into your oil sump. I agree with you that the guides can cause the chain to Slack but a lot of times the spring rubbing on the housing will cause it to break

[@chadkline4268]

@@FullThrottleJunkie at least, it's worth checking. I can't speak for every KLR.

[@FullThrottleJunkie]

@@chadkline4268 I can't speak for every kalar either but I have personally dug into for KLR650 engines and all four of them have had an issue with the spring and the mileage has ranged from 1k to 12k miles

[@zanebraunstein8366]

The EM torsion spring is useless. When the spring works its way out of the groove, which it will as it adjusts around, it hits the starter gear. Not good. Also doesnt give you correct tension. Not acting with leverage. Only upgrade is shorter spring and lever if required.

[@colt2206]

Wast of time and money. It’s the classic I had a friend of a friend who his broke. Just doesn’t ever break in reality. Talk to Kawasaki mechanics. It just never happens

[@rugby3874]

You don't need to change the doohickey on the gen 3. Its a bunch of bull. Your wrong.

[@FullThrottleJunkie]

It was a problem with the second gen as well I'm not going to be surprised when you're going to start seeing third gen with issues with the spring

[@billbonu1639]

Time lapse videos are absolutely useless to me.

[@FullThrottleJunkie]

its not a how to video

[@colt2206]

Nah the factory one is fine. Replacing it is kinda a scam

[@voytron1]

Its all bullshit Vulture Mike just wants to make money and scare every KLR owner. If it was a big deal Kawasaki would of done a recall

[@FullThrottleJunkie]

You should go watch my other doohickey video

[@dieseltu1035]

Money scam

[@FullThrottleJunkie]

i don't think so

[@wtr948]

The fact that Kawasaki hasn't addressed this issue ever means they don't give a shit. Why anyone would buy this bike is beyond me.

[@FullThrottleJunkie]

They have addressed it with the 2nd gen, with a thicker doohikey. But the problem is the spring. its a cheep enough fix to just do it your self. And its the best priced adventure bike on the market

[@wtr948]

@@FullThrottleJunkie Well you make a good point. It's relatively cheap so you can really ride it like you stole it and if you drop it here and there it's really not much to cry over.

[@supernova6677]

What a complete waste of time. Do you want factory parts or a bike "fixed" by these amateurs.

[@RMACIAS2460]

Over rated.

[@borisleak4890]

yawn.....

[@FullThrottleJunkie]

😂

[@TimothyCaldwell-mt5zc]

Literally nobody including mechanics have EVER even heard of this being an issue with proper maintenance.

[@omgitstiger]

Touche. Waste of time and money. Just ride the bike, do the adjustments at service intervals and your highly likely to be fine. As long term Kawi mechanic once said " if it,s making a noise bring it in". My gen 2 has 60,000 klms on it and purring still. It hasn,t exploded!!!!