'08 KLR Still Needs a New Doohickey

[SWriverstone]

Many may already know this, I just noticed (over on KLR650.net), so I'm posting it here as a "Public Service Announcement."

Word has gotten around that Kawasaki actually improved the infamous KLR "doohickey," aka the balancer adjustment lever. Pre-08 bikes had an inferior doohickey that has broken in hundreds of cases (at various mileages), so it's common knowledge that if you own a KLR, you seriously need to replace the doohickey with a superior aftermarket version. (Because a broken doohickey can lead to serious engine damage.)

Sadly, the '08 KLR still needs a new doohickey and spring. They improved it...but in the words of KLR expert Mike Cowlishaw, "They didn't finish the job." Mike (known as "EagleMike") manufactures the popular aftermarket replacement doohickey...but in case anyone thinks he's just trying to sell parts, that's not the case at all. Mike has concrete, irrefutable evidence and knows what he's talking about (he's replaced over 300 KLR doohickeys and has seen it all).

Basically, the '08 KLR has a much stronger doohickey...but the tolerances are loose—there is play between the doohickey and the idler lever shaft (which is not good). Also, the spring (which tensions the balancer lever) is too long in the '08 KLR—meaning after 3-5K miles, it'll just sit there, not providing any tension (not good).

For details, see EagleMike's excellent information here:
http://www.klr650.net/forums/showthread.php?t=27231

Scott

[JamesG]

Besides the more than a bit of conflict of interest there.
The KLR doohickey problem was never a consistant failure. Some would fail, some never would.  If the new dohickey spring could make it thru testing, then I would bet its fine.   While I DID invest in one of Mike' doo kits on my old bike, I wouldn't on an 08.

[R.Markus]

I would expect no less from someone who's product is dependant on there being a problem with the original part....so, ooooooh, they didn't fix it enough and you still need to buy his doohickey.  

[SWriverstone]

Ouch! You guys are dripping with cynicism!   Just out of curiosity, how would you react if you were shown physical evidence that what Mike says is true? Mike sells the replacement part for $40. He's not "dependent" on selling doohickeys, believe me. (Maybe enough money to pay a few bills now and then, that's about it.)

And equally, why would you suspect Kawasaki's engineers would produce a flawlessly-engineered part? (That's just as gullible as thinking Mike's replacements are unnecessary!)

I'm honestly not trying to start a fight. You're correct that the failure rate of the old doohickeys is nowhere near 100%. More like 20-30%. But it's documented fact that many engines have been lunched due to broken doohickeys—and this is an issue Kawi has never resolved under warranty. Mike sells his part as some insurance and peace of mind for $40. Heck, I'd do that—it's far less gullible than us paying hundreds (or thousands) to insure our bikes and cars!

Scott

[bmwone]

 If the new dohickey spring could make it thru testing, then I would bet its fine.  

Maybe I'm stating the obvious, but didn't the original doohickey "make it through testing" also?

[JamesG]

Yep, and if the old doohickey had failed during testing or in anything like a predictable or regular pattern, then they (KHI) would have revised the part long ago.

[BlueRidgeKat]

While I DID invest in one of Mike' doo kits on my old bike, I wouldn't on an 08.

Well, I wouldnt on a 08 either, at least not yet.

Has one failed on a 08 yet? Has anyone even had a 08 long enough to put 5,000k on one yet ? And if there is one out there with 5k on it already has the part failed ?

Its easy to tear into a 08 and say "this is no better" or "this spring wont be worth a shi_ after 5k" but personally I want to see a broken, worn or non working part from the new 08 before I would do this upgrade. Actually I'm pretty lazy so as long as the thing runs and nothing breaks probably wouldnt do it anyway, of course then its already to late.

Still unable to decide which looks best, the red or the blue one.

[august]

Definitely the red one!!!!!!!!!!!

My red one is waiting for me to pick up tomorrow.

[daddysbike]

Red for sure but I like the green even better



Steve

[1moreroad]

Definitely the red one!!!!!!!!!!!

My red one is waiting for me to pick up tomorrow.

How'd you like it this weekend?

[badger]

Somehow, if I'm buying a Kawa, green has the advantage.  

[august]

How'd you like it this weekend?

 

I had a great time. I am very happy with the bike. All of the improvements they made to the bike have been very worthwhile . Only have about 250 miles so far, but every time I get on it I am sure I made the right decision.

Thanks for asking.   August

[hovmaven]

I like the blue one.