Free Standing Offer: KLR Doohickey (San Antonio)

[tricepilot]

**NEW** See the FAQs at the end of this opening post.

If you own a KLR and haven't done the "Doohickey", this is an offer for free assistance in getting it and it's spring changed out.

We've been DOO-ing () quite a few of these lately and the picture inside some of these motors isn't pretty. Broken springs, slack springs, you don't know what you have until we take the case off your motor.

Contact me via PM and come to Casa Tricepilot. We'll get this job done pretty fast and you'll be back on the road with the confidence that your KLR is ready to rock and roll.

I have all the "Eagle Mike" KLR Doohickey tools and more, including rotor socket/puller, electronic torque wrench, monster breaker bar, etc. We can put your KLR under anesthesia if needed.

Oil drain is required: this means you need oil and a filter (unless your filter is new)

Eagle Mike Torsion Spring HIGHLY RECOMMENDED. There is no point in DOOING the DOO and just putting another factory linear spring back inside your motor.

Inner and outer case gaskets are a must in the event either or both tear

If you order from Eagle Mike here's your list:

Doohickie Kit less tools (includes doohickie, fixing bolt washer, and 2 linear springs you won't use)
New Rotor Bolt (highly recommended, but not 100% critical)
08 bikes and 09 with VIN earlier than 20800, ask Eagle Mike for the starter gear pin spacer
Inner/Outer Case Gaskets
Torsion Spring

Add to this your oil (2.5 quarts of any flavor you like) and a filter if you need one

NOTE: All 2008 and early 2009 engines have a starter gear cluster pinion deep hole issue in the outer case. This is the lower of the two holes. The hole is too deep and the cluster gear pinion has too much room to move outward. This can be fixed with a bushing that will fill the proper amount of space and keep the pinion from moving outward. If you order your Doo kit from Eagle Mike, he'll include a (free) bushing /spacer to remedy this. The last five of the VIN 20800 or below apply to 2009 bikes. Be sure to ask Eagle Mike for the free spacer.

NOTE: Here is the link to Eagle Mike's Doohickie install page LINK

This is a standing offer, not a tech day announcement, just contact me and arrange a time.

Bill's DOO replacement:





Brian's DOO replacement:







I'll be handing you the tools and guiding you step by step, thus the job goes pretty fast and you become a trademan with the ability to help others in this task.

DO THE DOO!

FREQUENTLY ASKED QUESTIONS

Q: How do I schedule with you?

A: Please send me a PM in addition to any posting in this thread. I'll see a PM fastest.

Q: What do I need to bring?

A: Eagle Mike doohickie, Eagle Mike torsion spring (highly recommended, but you can use a linear spring (not recommended), new rotor bolt, inner and outer case gaskets, oil, oil filter. You can get the doo, spring, bolt, and gaskets from Eagle Mike. He takes PayPal.

Q: I have every part except for the (rotor) bolt. Can we reused the bolt?

A: Technically, you can, but due to the stress placed upon the bolt by torquing it down, and the fairly precise nature of the torque spec, it is best to use a brand new bolt, available from Eagle Mike.

Q: Am I supposed to do anything to the bike before coming to your house?

A: Yes, you can speed things up by removing the engine bash plate. This is necessary because the bash plate interferes with the removal of the outer case.

Q: How long does it take?

A: We take our time and have fun with it, so about 2 hours, mas or menos.

Q: Do I get involved, can I help, etc.

A: In fact this is your job, I'm there for "guided assistance". You will be removing and replacing bolts, cleaning the case faces, etc. Although there are several critical steps where its just easier for me to do the work, such as removing and replacing gear clusters, removing and replacing the rotor, and making sure the idler shaft doesn't come out inside the engine.

Q: Can I ride my bike over to your house?

A: You can, but the engine needs to be cool-ish before we start. We can place a fan on the engine and go eat someplace first.

Q: Do you stock the parts?

A: No, you get them from Eagle Mike.

Q: How many of these have you done?

A: I've stopped counting, but over 20 easily.

Q: How much do you charge?

A: Nada, totally gratis, free etc. You are encouraged to post up in this thread when the job is done, telling the world what a wonderful experience you had.

Q: I live in this wonderful place and I have a spare place for you to come visit me. Why don't YOU come to MY house and make this a house call?

A: Ah, nice idea. But I don't do road trips to DOO the DOO.

Q: I'm selling my KLR and I want to do the doo to help resale value, is that a factor?

A: I really want to do these jobs for folks who are going to keep their bike with no plans to sell it. If someone is planning to sell the bike, please take your KLR to someone else to get it done. I do this so folks can enjoy having a well-maintained bike, not to assist in profit making.

Q: I can't make it over to your place, but my buddy can. Can my buddy help you do this?

A: Owner of the bike must be present and working on the bike.

Q: How can I find Eagle Mike?

A: At his website: LINK. You can also call Eagle Mike 619 697 1674 shop. 619 261 1281 cell

Q: You deserve some delicious beer for all this hard work What kind of beer do you like?

A: Right now the flavor of the week is Sam Adams, thanks!

Q: Do you loan your tools?

A: No

[Duke]

[tricepilot]

See edited opening post

[Valker]

What an offer...I want another KLR just to learn how to do this (other reasons are good too).

[The Bruce]

Do you have a collection of the broken parts that come out of the case on these Doos? My riding buddy thought his was fine and found a broke spring and a broken doo. He was lucky the cam chain hadn't let loose.

[tricepilot]

Originally Posted by Valker

What an offer...I want another KLR just to learn how to do this (other reasons are good too).

Originally Posted by CBAT

Do you have a collection of the broken parts that come out of the case on these Doos? My riding buddy thought his was fine and found a broke spring and a broken doo. He was lucky the cam chain hadn't let loose.

Let's just say that the majority of KLR DOO springs and levers are NOT in factory spec. That includes '08 AND '09 bikes.

I was intimidated at first when I did my own KLR mechanics. Then, I realized that the reason I bought the bike was to LEARN.

I would like to help other Texas riders LEARN how to wrench on their bike. The KLR is one of three bikes in the garage - KLR, BMW, Harley.

I have been taught by other, more talented mechanics. That is to say - most everybody I meet is a much better wrench than I am. But I love to learn. That's how I started wrenching - on the KLR. The DOO is EASY, once you've done it about 3 or 4 times. EASY! Now, I just want to keep the parts in stock to make it brainless to get this job done. AND IT NEEDS TO BE DONE!

Plus, I can make some killer GUACAMOLE when you come over:

My Guacamole Thread

[Loanstud]

Quite an offer I'd say... I'm on Lake Conroe though...

I need to do the Do and valves...

I can make the green stuff too as we'll as a red sauce.

Don't forget the Modelo after the job is done.

I do need some help though maybe a Tech day??

Perhaps another KLRer would like to head your way too!!

[tricepilot]

Originally Posted by Loanstud

I do need some help though maybe a Tech day??

Just say the word...

[PackMule]

I've been wanting to do this but, with my limited mechanic's skills, I'm a bit intimidated. I'll definitely take you up on the offer. I'll PM you to schedule a date sometime after TAR.

BTW, I also need to put on new tires. I imagine I can handle the front, but I've never taken the rear off. Could I do that at the same time... just in case I get stuck?

Paul
05 KLR650
04 KLR650
05 CRF230

[tricepilot]

Originally Posted by PackMule

I've been wanting to do this but, with my limited mechanic's skills, I'm a bit intimidated. I'll definitely take you up on the offer. I'll PM you to schedule a date sometime after TAR.

BTW, I also need to put on new tires. I imagine I can handle the front, but I've never taken the rear off. Could I do that at the same time... just in case I get stuck?

Paul
05 KLR650
04 KLR650
05 CRF230

Doohickey and tires in one half day, guaranteed....

[thumper_tx]

My best fishing buddy scored a mint o7 KLR in H town today.
2K on the clock and the Doo ain't been done.

Sounds like maybe another excuse for a fish fry/tech day.
He did help catch a lot of the fish we ate last Sat.

[tricepilot]

Originally Posted by thumper_tx

My best fishing buddy scored a mint o7 KLR in H town today.
2K on the clock and the Doo ain't been done.

Sounds like maybe another excuse for a fish fry/tech day.
He did help catch a lot of the fish we ate last Sat.

I will return to Smithville for fried fish in exchange for DOO change out

[thumper_tx]

After TAR for sure.

Will do another tech day before MEX Trek. Either May 1st or 8th.
Will post up asap when schedule is set.

[Tourmeister]

Hey guys, I am planning to host a Burger Bash May 1st here at my place in Huntsville. I have room in the garage and driveway to work on numerous bikes. I don't have the doo tools but have everything needed to do valves. However, if you plan to do valves, you need to trailer the bike as the engine needs to be ambient temp. You'll also need a wide variety of shims so that you don't have to order any after you get the valve covers off. I can also do tires, oils, chains and sprockets, brakes, bearings, etc,... If needed, folks can have stuff shipped here. We've done that in the past. Also, in case anyone needs to stay over, there are lots of hotels right close to our house. I'll be doing burgers and dogs and James Cain will be doing some of his homemade deer sausage. Get here early for the sausage as it goes FAST! I usually have folks start showing up at 10:00am and staying as late as needed. It will also be an open event for anyone (non dualsport) to stop by if they are out and about that day and they get lunch. I have plenty of room for parking LOTS of bikes.

Anyone interested?

Linky to event thread:

http://www.twtex.com/forums/showthread.php?t=47366

[tricepilot]

Originally Posted by Tourmeister

James Cain will be doing some of his homemade deer sausage

Great! I always wanted to meet that guy...

[tricepilot]

Has just refreshed my supply of KLR Doohickeys, gaskets, springs, etc. etc.

If you need this task done, there is no time like spring time!

[FatalException0E]

OK, curiosity is getting to me here...just what is the doohickey? Seen loads of talk about it, but never seen exactly what it is. As an outsider in the KLR world, I've never been initiated.

[tricepilot]

Originally Posted by FatalException0E

OK, curiosity is getting to me here...just what is the doohickey? Seen loads of talk about it, but never seen exactly what it is. As an outsider in the KLR world, I've never been initiated.

In a nutshell, it's a lever that permits adjustment on a shaft attached to a sprocket that keeps tension on the balancer chain inside the KLR engine.

The shaft itself is eccentric, which means turning it left or right either applies or removes pressure against the chain via the sprocket.

You want the right amount of tension on that chain, which is performed by spring tension.

The Doohickey spring attaches to the lever (the "Doohickey"), which itself is held in place by a bolt. Loosening the bolt allows the spring to tension the shaft, and ultimately the sprocket and then the goal: the chain.

Why Kawasaki is in denial about the quality of the spring and Doohickey inside their engines is long documented.

Even with the change to a billet material in '08, the springs still are prone to breakage. Prior to '08, the Doohickey itself was prone to breakage.

Replacing the DOO in '07 and earlier models is critical.

Replacing the DOO in '08 and newer models is almost as critical, as one local dealer opened up the side case on an '08 and found the spring wasn't even attached

[tricepilot]

If you want to see what it looks like, see the photos in my first post.

The Doohickey is the somewhat triangle shaped piece with the groove cutout (where the bolt goes for adjustment)

[tricepilot]