This motorcycle maintenance tutorial shows you how to adjust the balancer chain on a kawasaki klr650. The klr comes with rubber footpegs, which help to reduce vibration but for offroad situations the rubber doesnt often deliver the best footing. There has been some confusion about the balancer tensioner lever and spring on the 08 klr. Buy kawasaki klr 650 parts,klr650 dualsport parts,klr 650 enduro motorcycle parts,kawasaki klr 650 battery,klr650 brakes,klr 650 lever. The klr650 profits from a proper skid plate, crash guards or abs plastic tank, and hand guards real ones, with metal spines, for trail survivability. The doohickey engine idler lever counterbalance upgrade kit. I have asked mike at eagle machine for the info on his kit.
Happy trails motorcycle products happy trails motorcycle products specializes in manufacturing the finest custom engineered luggage systems and products designed to enhance the use, safety and enjoyment of dual sport and adventure touring motorcycles. Klr650 doohickey torsion spring install with eagle mike. We will show how to install a torsion spring to your klr650 balancer system, replacing the factory extension spring this setup is far superior to the extension spring setup. The 2008 klr650 felt easier to control at low speed when compared to my 2001. The rather fragile doohickey was beefed up for 08 and later klrs, but. Changed out the doohickey thing, its not a big deal. It was poorly designed and tends to break, as in ops photo. My dad just picked up an 05 klr 650, and i know hes read up on them, but he. Kawasaki klr650 service manual supplement pdf download.
In the pic im using an 18 volt impact driver for removal only. An absolutely free and advertisementfree website dedicated to the maintenance and enjoyment of the kawasaki klr650 motorcycle. Klr500, klr650 2000, klr650 2001, klr650 2002, klr500 2000, klr500 2001, klr500 2002. These, along with the stock took kit, is all you need to replace everything on the klr except for rotor and tires. During my emergency stop tests, the 2008 klrs forks performed the characteristic. So to help get better grip a set of ims super stock pegs were installed. Well start with a very popular upgrade to the klr650. This worked much better, and is the method i would highly recommend. Technical articles and maintenance procedures with accompanying photos to further clarify the process make this very much a diy resource for almost every level of mechanical skill. Kawasaki klr 650 parts kawasaki klr 650 dualsport parts. Get instant access to this online service manual, adjust the doohickey and maintain your klr650 dual sport motorcycle to keep. While the coil spring that comes with the doohickey is good, some people prefer the direct tension the torsion spring gives to the doohickey the coil spring connects to a small stock lever. Kawasaki klr650 motorcycle 20082017 service and repair manual. The right tools and procedure, as you might guess, make all the difference.
Zega evo aluminum touring pannier sold individually atlas throttle lock, universal motorcycle cruise control. Throw in a 32mm offset wrench, rotor puller, some rtv, and the tire tool kit and theres nothing you cant replace. I just completed the installation of the doohickey. How to install a kawasaki klr650 doohickey counter balance. I know that some people struggle with installing a doohickey torsion spring. I torqued all the bolts to the specifications in the clymer manual. See the latest prime klr650 items with free shipping. I followed the eagle instructions and everything went back together easily. The sprockets for the balancer chain are made of multiple parts, some of which have been missing, when the engine was opened for the first time. Doohickey install melbourne kawasaki klr 650 forum.
Universal cycle will continue to serve our customers while respecting the social responsibilities that keep our community safe all universal cycle employees are following hygiene protocols as directed by government guidelines. Matthew vandyke with his kawasaki klr650 motorcycle and an ak47 in iraq. Should i replace the doohickey in my nearly new klr650. Due to the unpredictability, i strongly suggest you just replace the stock mechanism on your klr 650 with a replacement doohickey right away. Klr650s have been known to have problems with the stock idle lever doohickey needed to keep tension on the balancer chain. Wrenching and mods klr650 technical discussion only. No real mechanical improvements have been made to it. Doohickey install melbourne howdy guys, new 2008 klr650 owner and have been trawling potential problems with the klr and as i plan on keeping it for a long time wanted to get the doohickey installed but having a hard time finding a bike shop thats done them before. Klr650 doohickey torsion spring adventure bike australia.
Here is a video on my 2007 kawasaki klr650 doohickey install and oil change. General information quick reference guide general information periodic maintenance fuel system cooling system engine top end clutch engine lubrication system engine removalinstallation crankshafttransmission wheelstires 10 j final drive 11 j brakes 12 j suspension j steering 14 j frame 15 j electrical system 16 j appendix. Offers improved adjustment range compared to factory parts. Kawasaki klr650 200820 service manual by cyclepedia. Weight the klr650 is not heavy, which is especially important for adventure touring where every pound counts when carrying gear. While we were filming our installation video for the new rmstator kawasaki klr650 high output stator, we noticed our test bike still had the original doohickey counterbalance chain tensioner. We offer engine parts from suppliers like ape, cometic, kawasaki oem, eagle mike and hot cams just to name a few. View and download kawasaki klr650 service manual online. Any balancer parts purchased from studebaker, mashonline, or klr650. Size the klr650 is a mediumsized motorcycle, easy to manuever both in traffic and in challenging offroad environments. This manual covers everything from rebuilding the forks to replacing the balancer shaft bearings on the 2008 and newer.
As many have heard from either the web or other klr enthusiasts, the bulletproof design of kawasakis klr engines have but one flaw. The thermobob 2 eliminates the inconsistent engine temperature prevalent on the klr650. This klr650 engine ate both exhaust valves, damaged the cylinder head, cylinder, and piston all because the doohickey was not adjusted correctly. Complete the contact information form below and we will contact you as soon as possible please do not just send me an email with your phone number and ask me to call you. The effort to thread in the puller and remove the rotor can be minimal, or quite a bit. Once youre sure all 4 spokes of the starter gear are going to clear the doohickey, you can remove it and install the adjusting bolt, tightening it to about 8nm 5.
Buy eagle mike klr 650 complete doohickey kit wtorsion spring, gaskets, rotor bolt. Any balancer parts purchased from studebaker, mashonline, or after late may of 2008 are not genuine eagle parts. Yesterday i went on a of road trip on a 2000 klr650 near rosarito baja california mexico, it was a 120 mile off road trip and i was lucky because everything went ok but i was a little nervous because i wasnt carrying any tools. Doohickey torsion spring is an alternate spring that can replace the coil spring that comes with the eagle mfg. The doohickey is the klr650 communitys term for the balancer chain adjuster lever. Genuine eagle leversdoohickies are h900 condition, and much stronger than the.
Our tubular custom side racks, aluminum panniers, tail racks, engine guards and highway pegs are mandrel bent and aircraft quality tig or mig. Lever is machined by eagle from high strength heattreated aerospace grade stainless. The first thing to do is slide the starter gear fully onto the shaft, and spin it slowly by hand to be sure all spokes clear the new doohickey. Mar 11, 2007 i just completed the installation of the doohickey. Balancer chain adjustment is a good procedure to do every other oil change when youre waiting for the oil to drain. Genuine eagle leversdoohickies are h900 condition, and much stronger than the h1150 condition currently advertised by. How to adjust the balancer chain on a kawasaki klr650. Dirtracks 19872018 kawasaki klr650 saddlebag support racks.
Doohickey installation problem klrklx 600650 thumpertalk. Kawasaki klr650 service manual pdf download manualslib. Steering system free delivery possible on eligible purchases. A high quality eagle manufacturing torsion spring puts more consistent force on the tensioner lever. A few passes with a file fixed this, and i was ready to continue the installation. I just installed them yesterday and it was well worth it, what a removal of the agonizing back sting i use to get.
Genuine eagle leversdoohickies are h900 condition, and much stronger than the h1150 condition currently advertised by klr650. Kawasaki klr650 service and repair manual 20082017 m2402 includes color wiring diagrams. The doohickey is a stamped metal part that uses a spring to apply tension to the engine balancer chain. I dont have a breaker bar, or whatever, so i just put a pipe over a ratchet. The stock lever is actually two pieces welded together to make the lever. It all fist into a model 2000 otterbox that easily drops into the bottom of a saddlebag.
May 31, 2017 while we were filming our installation video for the new rmstator kawasaki klr650 high output stator, we noticed our test bike still had the original doohickey counterbalance chain tensioner. The new pegs are made from 174 stainless steel and are covered with durable grey powdercoat. This lever has an adjuster bolt that goes through it and when loosened, allows the spring that is attached to the lever to remove the slack in the balancer chain. Touratech explore rear shock, kawasaki klr650 1987current. The early adjustment lever is a soft, stamped, one piece design. I followed the procedure written by the pioneer of doohickey. Get instant access to this online service manual, adjust the doohickey and maintain your klr650 dual sport motorcycle to keep it running in top form for your next adventure. Kawasaki klr650 motorcycle 20082017 service and repair. May 21, 2018 here is a video on my 2007 kawasaki klr650 doohickey install and oil change. I used the search box on the upperright of this web page, searched just the klr650 reddit on doohickey, then looked at titlessummaries that had newer models.
During my emergency stop tests, the 2008 klrs forks performed the characteristic klr650 nose dive, very much like the previous model. Free shipping, no hassle returns and the lowest prices guaranteed. This is an original eagle design, as strong or stronger than any other on the market. On mine, 3 of the spokes cleared easily, but the 4th was just kissing the top outer edge of the doohickey. In the 8607 klr650s chaindriven balancer subsystem, two related parts are prone to failure.
A couple of things to look out for, i installed the tpi risers and a fella told me to make sure the smaller end was facing down i dont know if it makes any difference, use thread locker and i think this trick will work, tighten one side all the way first, the other side will. The torsion spring that hooks into the adjustment slot is a 100 percent eagle design. This service manual provides specific, detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of the kawasaki klr650 motorcycle. Klr650 kawasaki klr650 doohickey thermobob thermobob 2. When that happens your engine chews up the pieces, or your balancer chain gets thrown. Allows the engine to maintain a consistent 195 degree operating temperature for better performance and longer engine life. The clutch was smooth and required little effort to feather, with a relatively normal klr friction zone. If you have a legitimate question, im happy to try to help you. The cyclepedia 200820 kawasaki klr650 digital service manual features detailed fullcolor photographs and kawasaki klr650 wiring diagrams, complete specifications with stepbystep procedures performed and written by a seasoned kawasaki dealer trained technician. Home kawasaki klr650 engine klr650 doohickey torsion spring. If you are or arent changing your oil now, check out the video and see how to adjust the klr 650 balancer chain.
Technical articles and maintenance procedures with accompanying photos to further clarify the process make this very much. Replace oem doohickey and spring with aftermarket components from eagle mike. While we were filming our installation video for the new rmstator kawasaki klr650 high output stator, we noticed our test bike still had the. View and download kawasaki klr650 service manual supplement online. One of the best answers is the doohicky is good for 50,000 miles, plus or minus 50,000 miles.