UK Doohickey...
 

Hi folks,
I have recently acquired a 1985 KLR600. just to get to know it better, I have decided to check out the infamous doohickey and replace it with an aftermarket item. Is there anyone here who has done this procedure in the UK who is willing to lend/sell me the rotor puller bolt & wrench.

Also, if anyone has any stuff for sale like a large tank, luggage, sump/radiator guards - please let me know and we may be able to do a deal.

Kind regards,

Bal.

in case you manage to get access to an impact wrench, you do not need the special wrench. That's what they do at the dealership.

Bal,
Whereabouts are you in the uk?

Bol,
Just south of Leicester.
regards,
Bal

Bal,
I may be able to get them to leicester for you to borrow, but will need a cash deposit for them.
Bol

[This message has been edited by Bol (edited 13 December 2003).]

Bol,
Cheers. I would be willing to collect or pay for any P&P. Deposit is no problem. Drop us a line. my email is either the one above (work) or bschazmann@hotmail.com
The hotmail one is the one that I will have access to in the next 2 weeks.
All the best,
Bal.

I know this was posted a while ago, but I'm needing to change the doohickey on my KLR next Saturday and forgot about the requirement for that 'special' tool. Any chance you still have it for hire?
Thanks.
Michelle.

doohickey - di - doo
 

Now and forever:

To get the flywheel off a KLR you need to see a good hardware shop specializing in bolts & nuts:
Get a bolt of the dimension M22x1.5 with a thread lerngth of approx 50mm and a hex head.
Next you take the generator covers off and push the bike to the next truck workshop. With the M22x1.5 bolt and the workshop's pneumatic impact wrench the flywheel is off in a few seconds. Note: This flywheel puller works on a wealth of jap bikes as the M 22x1.5 puller thread is some kind of japanese standard.
Perfectionists might file or lathe cut the end of the bolt rectangular to its axis.
The bolt is cheap and usually comes in high tensile steel (12.9) and therefore to prefer to a selfmade flywheel puller. My selfmade puller gave up on a very tight sitting KLR flywheel two weeks ago after 20 years of reliable service on various jap bikes :-/
If you can't get hold of a pneumatic impact wrench you will have to make a flywheel holder:
Take a good quality 36mm open box (one forked end one ringed end) spanner (like Stahlwille Alloy series)
Take a acetylen oxytorch and after clamping forked end in vice make red hot just above and bend into a Z shape to get forked end to sit on flywheel, shaft to curve around flywheel and ringed end to rest under or on top of footpeg. You will have to give the spanner a shape to make the ring come into plane with the fork otherwise the fork will slip off the flywheel when under load. This tool is extremely helpful for torquing the flywheel during assembly, bit reluctant to forge it on with impact wrench:-)

Don't use cheap shit spanners for the flywheel holder as they will break and hurt you. (Esp. after heating and bending them).
Allow the spanner to cool down naturally after bending. NO WATER!!!
Don't use spanner with two forked sides. The flywheel holder sometimes does slip. It hurts!

The flywheel often sits extremely fast. If no impact wrench is around make sure you have people holding the bike and pipes to extend spanner on flywheel puller to stand on top of:-)

Have fun!