KLR 650 Doohickey Upgrade

[ChucksWorldofFishing]

yeah soda !

[kidcycle3130]

I changed my doohicky and installed the torsion spring this weekend. I read a step by step procedure and then watched your video. I was ready to refer to your video during the install but I was able to make my way through the procedure without having to refer to it! Hardest part for me was getting the rotor lined up with the woodruff key! Thanks for the video... very helpful to me.

[vsginaz]

Just a clarification, I used my centerstand! Thanks again! Great video

[vsginaz]

Just a quick thank you from here in AZ! Your video made it fun and easy! I did it while on the kick stand. I have yet to put new oil in it this morning, since I did a bunch of other stuff while in service mode: stronger 12.9 sub-frame bolts, carb T-mod, & 16T front sprocket. I love my KLR! I used a smallish electric screwdriver with a sensitive trigger to cut down on the wrenching time. I also used the card board trick to keep track of the screws. Lastly, I only had 9 inner bolts. Thanks

[hellcat650]

Nice work. I'm hoping to tackle my 2011 soon...

[haijec]

Thank you for making this video. I just Did my Doo last night and your vid proved to be an indispensable tool. Cheers

[GrizzlyJetDude]

Whoa. Dood! Very impressive. It zipped by a bit fast, but then again I guess I'm not watching an ep of American Chopper. Now I really know what I'm up against. Thanks!!

[SteveD328]

Eagle Mike parts are the best. Did the doohickie on my KLR a couple of months ago just as a "precaution". When I took the cover off for the first time, I found that the factory doohickey had long since FAILED!! Much less noise from the engine now, as the balancer chain now has the proper tension.  The doohickey should always be upgraded, even on brand new bikes.

[onehitkill]

where do you order the parts? i went to the kawasaki dealer ship and they told me i dont need to change that part lol! they want me to screw my bike up so they can rape me when i take it to them to fix it!

[ghotioutofh2o]

@onehitkill Please see the video description.

[Shincism]

Cheers for the video mate, before i watched this i had some faith in myself, i now know im going to completely fuck this up! hahaha. nah but seriously, excellent video.

[ghotioutofh2o]

@blazeemupppp Umm, what?

[Shortstory123]

Hi, I'm in the middle of doing my "doo," and I pulled the rotor bolt off finally! Now I want to pull the rotor itself off. The wrench keeps slipping every time I go to tighten the rotor puller. ...any ideas as to keep the 1and1/4 inch wrench in place and not slip??? Are there other tools out there that could take the place of a rotor puller and get the same job done??? Can I slip a piece of wood or a cloth covered screwdriver in the teeth of the gear behind?

[ghotioutofh2o]

Not that I know of. Mine kept slipping off too. You just need to hold it really securely.

[Shortstory123]

@ghotioutofh2o Thanks anyway! I'll think of something... I hope!

[Shortstory123]

@ghotioutofh2o I'm sure the answer isn't to buy another barrel wrench, but I sure am tempted

[OneDudeProductions]

Hi, I am ready to do my Doo and wanted to ask you where did you get your torque wrench from.

Thank you.

[AngerIsOurGift]

This is pretty intimidating.

[calexander230]

Good video.

[7jocco]

My bike would run just fine except a few times at idle it would stop dead as a hammer. Today I pulled the side cover to find the tensioner lever (Doohickey) broken in half. It seemed to run fine when I pulled it into the garage. Do You think I was fortunate enough to have avoided engine damage? The timing chain and gears look fine and, like I said it seemed to run fine.

[ghotioutofh2o]

@7jocco Very fortunate.

[floydiangreen]

ah ok, thought you might have to drill it using a drill press.

[ghotioutofh2o]

@floydiangreen Nope, just a regular drill.

[floydiangreen]

yeah but you do not show the drilling of the hole and the fitting of the spring

[ghotioutofh2o]

@floydiangreen Can you work a drill?

At 6:08 , I point to where I drilled (with the supplied drill bit that I showed).

At 6:16, I have the hole drilled and show how the spring fits in.

Starting at 7:27, I describe torsion spring aspect of the installation, then several seconds later, at 7:34, I point to where the free end of the torsion spring goes. Not gonna lie, but it's a bitch to get seated, and that's using both hands. I couldn't hold the camera and seat it too.

[ghotioutofh2o]

@floydiangreen Maybe I'm missing your point...?

[floydiangreen]

do you get detailed instructions if you buy from eagle mike?

[ghotioutofh2o]

@floydiangreen The instructions shipped with the parts reference the same pages that I do in the video description.

[floydiangreen]

i have a 2010 model, which is better torsion spring or traditional doo upgrade?

[ghotioutofh2o]

@floydiangreen I'm a fan of the torsion spring myself.

[Inuktuuk]

I have a 94 and the Adjuster bolt doesnt have a washer, should I add one? thanks great vid!

[ghotioutofh2o]

@Inuktuuk Couldn't hurt I don't think. If you got a kit and it came with one (which it probably did if you got it from Eagle Mike, might as well use it.

[Shortstory123]

Thanks for the vid! Great job! ...OK, I have my kit at home. I noticed you have a footnote in your vid to drill at the 7o'clock position not the 5 o'clock position... that's exactly what my instructions show on photos that were sent with the parts. Is this the case??? I just need to know before I go thru all that work. Also what does that torsion spring look like, once on, and rapped around the doohickey? R U able to send any pics? The CLYMER manual only seems to work with OEM parts.

[Shortstory123]

@Shortstory123 I would like to add... the CLYMER manual is pretty vague and doesn't seem to cover any upgrades or problems found on the bikes over the years, at least mine does not appear too.

I ordered the manual thinking I was going to jump right in, start reading, do the doohickey upgrade and repair my bike... Not true!

again thanks for the vids!

[tony839294]

Had my laptop in the garage and did the job with this video. Great Job!

[ktimco]

This video was very well done, do you know if this procedure is the same for a 2009.

[ghotioutofh2o]

I believe it is that same for the 2009.

[GlobalMafiaWatch]

when i take off the flywheel bolt do i need to put in a new one when i put it back together?

[ghotioutofh2o]

It is recommended that your replace it. I replaced mine. I got it from Eagle Manufacturing (link in the description).

[larryspielfogel]

great video very helpfull

[O7ROADKING]

Great video Thanks for posting

[noblehops]

Pfft, vxe that was fully un-gracious. Thanks for doing this, it was super helpful, and I did not have any problem watching it, nor did it bother me in the least.

[ghotioutofh2o]

Thanks!

[Rockynight]

Thank you sir!

[ruckerd2324]

I guess if a bike is only 5600 bucks new...ya got to finish building it yourself? Wish I had seen this before I just bought mine!!! It would have kept me from buying it as I'm NO mechanic! I guess I've always jokingly called em "Sakahockys" for a good reason without knowing it! The fact it has a part called a "doohicky" says it all doesn't it?LOL...back to my BMW's I guess. Thanks for your info tho....

[BnSRTVguy]

Nice to see how i have to try to fix mine soon ... THX

[DecaPierce]

does this mod have any performance gain?

[DogmaticShrew]

@DecaPierce No, just eliminates a potential problem down th road.

[daskraut666]

good vid, thank you.

[flxibl2008]

Still not seeing the completed installation. How did you get the torsion spring around and into the doo??? that is the most difficult part from what I have read. Would be nice to see how it is done and how it looks when it is done.

[gpzDave]

Thanks man! I was trying to follow all sorts of forum advice... not easy. A vid is much easier to follow, well done!

[vxe6vxe6]

Dude, your camera looks like it was held by a spastic on crack.

It's really fucking hard to watch.

It would have been a lot better if you would of had an overview shot for the entire disassembly, then reassembled it and then pointed out the pertinent bits of information with closeups as you disassembled it again.

Don't get me wrong, the information is excellent, the execution sucks donkey balls.

[ghotioutofh2o]

A spastic on crack made me laugh. :-)

Otherwise, duly noted. Thanks.

[TranceCommunicator]

@vxe6vxe6 maybe you need crack too, and all it´s ok ;)

[fiddyduke]

good vid, but what an embarassment for Kawasaki, imagine after selling that bike for 20 yrs they have'nt improved this flaw. I guess that's why they sell them so cheap. A Honda would never need something like this.

[aerofart]

Awesome video and explanation.  Thank YOU!

[ALLTHEDORKS]

i called the cycle parts department; i thought after 20 years of kawasaki

using the stupid balancer adujstment lever they would have known what

i was talking about" but no" they dont... disapointing. but it is silly why the hell

are we calling it a doo hickey??

[flxibl2008]

@ALLTHEDORKS

Or a bouncer for that matter. wish it would have shown the new part installed, all I could see was the crankshaft.

[ghotioutofh2o]

If you're talking about the seeing new doohickey installed, watch from 7:20 to 7:39.

[K2MFW]

Thanks for the great video! My 2007 KLR-650 had no signs of doohickey failure, but decided to change it anyway. Found a broken tensioner spring. All in all, after replacement the bike was much quieter, and much safer now. Sure would be ugly to have a rear wheel lockup due to something nasty happening because of a broken spring or doohickey. Thanks Again! Matt - Millville NJ

[ozark333]

So does the KLR 250 ( 2000 ) have this same problem and does the same upgrade work for it also???? Thanks! Great video!

[ghotioutofh2o]

It's been a long time since I've had a KLR 250, and I never delved too far into it. So... I'm not sure. Sorry.

[7jocco]

I watched another youtube video where a guy had such difficulty removing the rotor on an 08 that, He wound up heating it with a torch. Have You ever had this happen or, heard of it happening ?

[mariswas]

good job man

[tikilino]

Great Video!!

One request: is it possible for you to suggest any adjustements to ride bikes in high mountains with less oxigen? I Chile its often to find nice trails over 3500 mts high over sea level.

Thanks

Mike from Chile

[RFRUS]

Dynojet in the US makes a jet kit specifically for high altitude. I live at 1 mile + altitude in Colorado and always rejet my bikes, otherwise they run too rich.

[depjim94]

@tikilino: I've got a KLR 650 and put in a K&N air filter and had no troubles in the Rocky or Unita Mountians at 10,798 Feet elevation.

[ALLTHEDORKS]

lean up the fuel air mixture!!

[eisenbaum]

Very helpful. Thanks for doing this.

[laserbulllet]

quick question for ya. Is it neccesary to upgrade the doohicky. I picked up a klr with 12k and wondering if it must be done. Is there a way to know if it needs replacement?

[ghotioutofh2o]

The doohickey failure is sort of hit and miss. I did it for piece of mind. My doo and spring were intact when I opened up the engine (so were two others I did, the fourth had a broken spring). I would do to doo.

[DeutschesAhnenerbe88]

Just curious is anyone knows why my bike is making a fast buzzing noise when I try to start it? Lights work fine, but she won't crank over? Battery?? Any help is appreciated! By the way, it's a 2000 with 62,000KM on it.

[bandguy360]

stop puting mechanix out of business!!! ;)

[evanparker]

"well...it should be green, if it isn't all covered in crap..."

[58781icky]

Do the KLR 250 have these Doohickey things also? and if so how mucj are the upgrades? My KLR 250 is a 1991

[navchrstn]

where do you get the special tools from?

[bigblock44s]

you make them. metal bends with heat. even if drop forged

[ghotioutofh2o]

Eagle Mike. Please see the description.

[Mulyanis77]

Thanks for this- I'll be doing one soon and my laptop will definitley be there with your demo loaded :)

[hotdogsandwiches]

VERY INFORMATIVE!

[cryostallion]

do i definitely need to put in a new rotor bolt when i do this?

[coflax99]

you rule dude,muchas gracias, estamos aprendiendo mucho.

[ClymerManuals]

Very nice, Great info! I think those attempting this would benefit form having a shop manual. BTW, Clymer is releasing manual for the new 08-09 KLR650.

[imacrazydude9999999]

why would you back out the bolt before you torque it? Is the new doohickey a different material, what's the difference? I thought it was a part that spun to counterbalance the engine but I'm wondering why you stick that bolt through the slot... cool video

[elephantcup]

This part doesn't spin. It just takes slack out of the chain that does spin. As the balancer chain wears/ stretches and the guides wear, it gets looser/ noisier. Once every 12,000 miles you loosen the bolt accessed from the outside, the spring pulls on the "doohicky" and takes slack out of the adjuster and pulls the chain tight again, then you very gently re-tighten it. It's just like a cam chain tensioner except that the cam tensioner is automatic, this is manual (why, Kawasaki??).

[ticlide66]

it is the same for klr650 2009??

[whipartist]

Thanks for this and all of your KLR videos. I am really enjoying them and learning a ton. I O U many beers. Ride Safe and keep up the good work.

Cheers

Kevan

[xxkodiakx]

thank you nice video how long does the stock set up last?

[ghotioutofh2o]

It really depends on the luck of the draw. There isn't a set time.

The sooner, the better.

[raybanman]

Thanks for this! Nicely explained! Its nice to see it done, as the manuals are pretty abstract most times!

[hclimb898989]

thanks for taking the time to do this..... i love the doobie safe project comment! hahah

[ronny2471]

I will be using this when I do mine : ) thanks

[metricinch]

i will be doing this at the upcoming washougal td. i already have the parts from Mike. i can't wait to crack it open and see the inside!

[spuck1234]

i have a 2006 klr 650 with 5400 miles on it. How would i know when to do the doohickey upgrade.

[ghotioutofh2o]

Pretty much if your bike has more than 1 mile on it, it's time to change it.

It really depends on the luck of the draw for which doo or spring will break and which won't. In my mind, it's better to just do it and get it out of the way. If you don't, there's a much greater possibility of something breaking and causing lots of engine damage.

[BigFatDaddy27]

Well done!...the Doo is ordered for my 08

[racerxs]

Thanks for going through the trouble of creating this great video!

I was a bit apprehensive before seeing this, now I am definitely doing it.

[motonegros]

What about us non-drinkers, do you think this is a 'doobie-safe" project? Or would a joint leave one too confused to continue?

[ghotioutofh2o]

I'll leave that up to you to find out; I have no experience in that regard.

[planetmike99]

Had a LOT of help but I and did this upgrade yesterday . This video NAILS the job (even if you breezed by some of the things I had trouble with, like stretching that torsion spring around to catch the corner of the doo.) I'd say it's a LITTLE more difficult than you make it seem, but everything is here. If a guy had the couple special tools you need, I think he could go right through the job with this vid. Thanks.

[wmock1]

Did my doohickey upgrade today on my 2007 KLR650. When I took everything apart to get to old doohickey, found that the spring had good tension and the old doohickey was in good shape. (4800 miles) Went ahead and put in new doo and torsion spring since the hardest part is getting to it. The hardest part of the process was getting the rotor off and getting the new torsion spring in place. The rest was pretty straightforeward by using your video and Eagle Mike's instructions. Thanks for the help!

[bluehighways77]

excellent video. I'll use it when I do mine on my '08.

[acraze21]

cool video, ill have to favorite

[ghlacy]

Thanks for all the videos. They are all great.

[james2macd]

I own a 2000 KLR 650 and have heard about replacing the doohicky. My question is WHY? What problems can the doo cause? Ill buy the parts and pay you to install. Just one small catch. You have to come to Costa Rica. James

[guyNbluejeans]

Seriously, how much would you have to have to do my 2005?

[ghotioutofh2o]

If you supply the parts, I'd do it for free.

Donations are always a plus; not gonna hold anything against you, though. :-D

[echotoday]

Great video. I've heard horror stories about these things rolling around in the engine cases. 5 stars

[dudeman659]

good job on the video. i have an 07 650 and i have been thinking about doing that mod among others. and it looks really straight forward! thanks again for the enlightenment!

[PeteRosenburg]

Woodruff keys are the devil.

[vorhese]

Having just fallen victim to the abyss of doom on my '08 (I dropped a 10mm socket down it), it looks like I'll be doing all this. And hopefully finding the 10mm socket inside the inner cover!

[hedlundk]

Thanks for sharing that. It looks do-able for someone with a modicum of skill.

[thedownwardmachine]

Do you happen do know if this video is also accurate for the 2008? Btw, thanks for the video! Five stars!

[ghotioutofh2o]

I should be, for the most part. There are a few minor differences that are pointed out in the video description (torques, small washer supplied with the kit).

[mauser1]

Does the new 2008 models come with the improved doohickey or did they keep the old style? Thanks.

[ghotioutofh2o]

The way I understand it (2nd hand knowledge, FYI), the '08 doohickies are somewhat improved, but the associated spring is not. The guy that manufactures the new doos (Eagle Manufacturing) has found instances of the '08 spring having no tension left after only 400-ish miles. I think the doo might still be a little loose on its perch. He still recommends the upgrade, as it is a better fit.

(I personally can't confirm any of this; he's the expert on this.)

[ghotioutofh2o]

(I'd trust his judgment on this, BTW)

[etboygb]

Brilliant. Thank a lot!

[Bshelton18]

nice soda heh

[steve68steve68]

Great video!! Thanks for taking the time to do this - it really helps those of us who haven't done it to see what's involved before getting dirty/ in too deep.

I'm sure if I did it, my vid would have a lot more yelling and swearing.

[ianrota93]

nice man!! great 'write up'

[MRSketch09]

WOW! What a very informative Video. Thanks for sharing the experience with the rest of us.

[everlast666]

WOW!! i thought it was easyer!! but i am going to do it!! as soon as i can get my hands on an Eagle Mike kit!!!

great video!

[dirtbag801]

Great job man... Thanks for your time.

[Propfrwrd]

Awesome! Thanks!

[terylsdad]

Excellent how-to video and write-up! Thanks for taking the time to do these informational segments! :)

[chowhound3]

Good job on the video, I downloaded it for when I do mine, again nice job

[helidon]

another great DIY! greetings from Greece!

[waschnurr]

Excellent video ghotioutofh2o. I have the right tools and now the confidence to go ahead and change the doohicky