nklr: travel advice

[Dirk Beer]

hello i took off the left side engine cover to check the doohickey yesterday. the doohickey looked intackt (4900 miles), but when I loosened the adjuster bolt, the doohickey just flapped in the wind (well ok, rotated freely when i pushed it, anyway). a few questions: 1) this means the spring is missing/broken, right? 2) the doohickey also moved a lot on its shaft. isn't there supposed to be a circlip holding it in place? 3) i rotated it as far _clockwise_ as it would go before tightening the adjuster bolt & putting the cover back on. was that the right direction? at the time that seemed right, now it seems wrong. i seemed right at the time because there was no adjustment left in the counterclockwise direction. thanks in advance for your advice Dirk A18

[Eric L. Green]

On Mon, 25 Oct 2004, Dirk Beer wrote:

> i took off the left side engine cover to check the doohickey > yesterday. the doohickey looked intackt (4900 miles), but when I > loosened the adjuster bolt, the doohickey just flapped in the wind > (well ok, rotated freely when i pushed it, anyway). a few questions: > > 1) this means the spring is missing/broken, right?

Yep.

> 2) the doohickey also moved a lot on its shaft. isn't there supposed > to be a circlip holding it in place?

Nope. It just sits on the shaft. The side cover keeps it from coming off the shaft.

> 3) i rotated it as far _clockwise_ as it would go before tightening > the adjuster bolt & putting the cover back on. was that the right > direction?

Yes. Sounds like you need to get all the doohickey stuff and fix your doohickey. Even if the doohickey itself is currently okay, the aftermarket ones are so darned tough compared to the stocker that you'd have to be an idiot to put it back in there after taking everything apart to get to the spring. -E

[denvowell@aol.com]

Did you find the missing spring? Dennis A18 the big red 1 [Non-text portions of this message have been removed]

[wannabsmooth1]

--- In DSN_klr650@yahoogroups.com, Dirk Beer wrote:

> hello > > i took off the left side engine cover to check the doohickey > yesterday. the doohickey looked intackt (4900 miles), but when I > loosened the adjuster bolt, the doohickey just flapped in the wind > (well ok, rotated freely when i pushed it, anyway). a few questions: > > 1) this means the spring is missing/broken, right? > > 2) the doohickey also moved a lot on its shaft. isn't there supposed > to be a circlip holding it in place? > > 3) i rotated it as far _clockwise_ as it would go before tightening > the adjuster bolt & putting the cover back on. was that the right > direction? at the time that seemed right, now it seems wrong. i seemed > right at the time because there was no adjustment left in the > counterclockwise direction. > > thanks in advance for your advice > Dirk > A18

To adjust it, only loosen about 1 turn - no more. The spring SHOULD pull it closckwise - so when you puch CCW, it should push back - else it's broken. The circlip was only used with the 1st generation stamped (very thin) levers. Later models that still had the shorter idler shaft (also shorter bearing for the idler sprocket), yet used the later lever, still had the groove for the circlip, but did not use it. The later lever is to thick to use the clip. Clockwise tensions the chain - pushing the bottom of the ever (hickey) to the left. all the best, Mike

[dooden]

http://klr6500.tripod.com/doohickey.htm Give this a read over, should clear things up. Might be just a weak spring, which are available in different lengths now. Jake sent me 2 shorter springs in the mail a while back for when the next time I open that side up and discover there is no pull left in the stock length spring, which I expect to find. Dooden A15 Green Ape

--- In DSN_klr650@yahoogroups.com, Dirk Beer wrote: > hello > > i took off the left side engine cover to check the doohickey > yesterday. the doohickey looked intackt (4900 miles), but when I > loosened the adjuster bolt, the doohickey just flapped in the wind > (well ok, rotated freely when i pushed it, anyway). a few questions: > > 1) this means the spring is missing/broken, right? > > 2) the doohickey also moved a lot on its shaft. isn't there supposed > to be a circlip holding it in place? > > 3) i rotated it as far _clockwise_ as it would go before tightening > the adjuster bolt & putting the cover back on. was that the right > direction? at the time that seemed right, now it seems wrong. i seemed > right at the time because there was no adjustment left in the > counterclockwise direction. > > thanks in advance for your advice > Dirk > A18

[Dirk Beer]

On Mon, 25 Oct 2004 19:56:54 EDT, denvowell@... wrote:

> > Did you find the missing spring? > Dennis A18 the big red 1

No... I couldn't see much with just the outer cover removed. I'm hoping it's either still attached at one end or sitting in the bottom of the engine.

[Rodney Copeland]

I was happy to the point of tears to find all six pieces of my Crumbled Doohicky and Spring with a magnetic retriever. Whew! Praise the KLR Gods! Rod,, hopin many don't procrastinate for 23,000 miles like he did!

--- In DSN_klr650@yahoogroups.com, Dirk Beer wrote: > On Mon, 25 Oct 2004 19:56:54 EDT, denvowell@a... wrote: > > > > Did you find the missing spring? > > Dennis A18 the big red 1 > No... I couldn't see much with just the outer cover removed. I'm > hoping it's either still attached at one end or sitting in the bottom > of the engine.

[Richard Hubbell]

Hi all, This doohickey problem seems to have gone on for a long time. I was wondering if anyone has heard from Kawasaki about the problem? Does the part get replaced free under warranty on a new bike? Would Kawasaki respond if all KLR owners sent them an inquiry? Is the problem just inherent in the design? e.g. Airplane radial engines are known to leak oil and it is a problem inherent in the design. Maybe the KLR market is so small that Kawasaki just doesn't want to spend the money on engineering a proper solution?? __________________________________________________ Do You Yahoo!? Tired of spam? Yahoo! Mail has the best spam protection around http://mail.yahoo.com

[Me]

Back in August and November of '05, I sent 2 emails to Kawasaki asking about this problem and if there were any plans to correct it. The ignored both. --- Richard Hubbell wrote:

> Hi all, > > This doohickey problem seems to have gone on for a > long time. I was wondering if anyone has heard from > Kawasaki about the problem? Does the part get > replaced free under warranty on a new bike? Would > Kawasaki respond if all KLR owners sent them an > inquiry? Is the problem just inherent in the design? > e.g. Airplane radial engines are known to leak oil and > it is a problem inherent in the design. Maybe the KLR > market is so small that Kawasaki just doesn't want to > spend the money on engineering a proper solution?? > > > > __________________________________________________ > Do You Yahoo!? > Tired of spam? Yahoo! Mail has the best spam protection > around > http://mail.yahoo.com > > > Archive Quicksearch at: > http://www.angelfire.com/ut/moab/klr650_data_search.html > List sponsored by Dual Sport News at: > www.dualsportnews.com > List FAQ courtesy of Chris Krok at: > www.bigcee.com/klr650faq.html > Member Map at: http://www.frappr.com/dsnklr650 > Yahoo! Groups Links > > > > > > >

test'; "> __________________________________________________ Do You Yahoo!? Tired of spam? Yahoo! Mail has the best spam protection around http://mail.yahoo.com

[dooden]

--- In DSN_KLR650@yahoogroups.com, Richard Hubbell wrote:

> > Hi all, > > This doohickey problem seems to have gone on for a > long time. I was wondering if anyone has heard from > Kawasaki about the problem? Does the part get > replaced free under warranty on a new bike? Would > Kawasaki respond if all KLR owners sent them an > inquiry? Is the problem just inherent in the design? > e.g. Airplane radial engines are known to leak oil and > it is a problem inherent in the design. Maybe the KLR > market is so small that Kawasaki just doesn't want to > spend the money on engineering a proper solution??

Basically yes... the upgrade is not very costly and provides piece of mind out of the weak spot of the KLR engine. Now go ride it.. . Dooden A15 Green Ape