Doohickey dee doo...
 

Just wanted to find out what recent experiences exist with the doohickeys?

My older KL650C's had some problems over the years with the locking plate of the balancer chain tensioner breaking where the bolt clamps it. The earlier locking plate is not available any more and has been replaced by an improved part a while ago.

My 2004 / 2005 KLR's were without any problems until a few weeks ago when one of the bikes started making the typical noise.
I found the locking plate perfectly fine and the chain well within wear limits but the spring (although the thicker later version) snapped.
Just stuck in a new spring and everything's fine.
Mileage is 35000km

Do the newer doohickeys still break or is the problem reduced to the springs?

just wondering about the doohickey
 

Thought I'd kick this thread up as my 2002 klr is over 33,000k with no problems to date, but I noted this is the mileage when other klr owners indicated problems with the part in question. I am going to have the doohickey checked before starting on another long trip this summer. Anyone have any actual experience with this part that they would like to share. I am beginning to wonder how much actual failure occurs with this, and how much replacement is just preventative measures because of the "reputation" of the part.

Fair winds and good roads to all,

Narly

I don't own a KLR.

There are reports from riders I know (pics of the broken parts included) about late models still having this problem.

If I owned a KLR, I'd change this part which has a long history of failure...and messing up your ride plans. It's very cheap insurance.

I have a 2000 model. doohickey discovered broken at 15000 miles (spring intact). I would upgrade these parts. I do not believe kawasaki has ever acknowledge any problem concerning the doohickey therefore I doubt any change in it's manufacturing has occurred over the years.

Do It :)
 

The original doohickey on my 2002 KLR shattered at about 20,000 miles (the pieces came out during an oil change, so it may have occurred a few miles earlier). Install the upgraded doohickey & spring before your trip and you'll keep on enjoying a problem-free bike.

James

I'm a beleiver
 

Thanks guys, I'm a beleiver. Who's the best source for the up-grade?

For all things KLR: Fred at Arrowhead Motorsports in Moab, Utah.

http://www.arrowheadmotorsports.com/

James