KLR650 Doohickey (Balancer Idle Lever) Parts & Tools All Years

Doohickey parts and tools, all years. WE ARE ONLY OFFERING THE TORSION SPRING, Choose options below

$39.95
SKU
MCYKLR-EM-10

If you have the lever and want the torsion spring only, go HERE.

Rotor Bolt: Add a new rotor bolt (OEM Kawasaki) for $12.95. Kawasaki recommends replacing it with each installation.

Magneto Cover Gaskets: It is a good idea to have both magneto cover gaskets on-hand in case you find they're leaking or they break when removing the magneto cover. OEM Kawasaki, $18.95 each.

Rotor Holder Wrench: This wrench is required for the upgrade. It is used to hold the rotor so it can be removed and reinstalled with proper torque on the rotor bolt. Equivalent to OEM Magneto Holder 570001-1184.

Rotor Puller Tool: The Puller tool allows for pulling the rotor without damage once the rotor bolt is removed. Equivalent to OEM Magneto Flywheel Puller 57001-1185.

Doohickey 101 - In the '86-'07 KLR65's chain-driven balancer subsystem, two related parts are prone to failure: 1) the balancer idler lever (Kawasaki part no. 13168-1436); and, 2) the idler shaft spring (Kawasaki part no. 92144-1860). The two parts serve to maintain tension on the balancer chain. The OEM idler shaft lever is a welded piece. Because it is improperly supported, the lever can be easily crimped, dented, or warped. Eventually, the damage can become so severe the lever "hangs" on the crimped part and fails to allow adjustment to the chain tension. In some cases the weld fails or the collar breaks so the lever is no longer attached to the idler shaft and pieces fall into the oil sump below. Tension on the system is now held entirely by the idler shaft spring. Under tremendous stress, the spring can fail either by breakage or being stretched beyond limits. In any of the above scenarios, when tension is lost the chain is capable of jumping a sprocket, jamming and locking the engine. It is also possible for the broken pieces to find their way into the oil pump (assuming the protective screen is missing) and cause engine failure at speed. What about the 2008+ KLR650? The balancer idler shaft lever is improved but not nearly what it could be. But even more important, the factory extension spring is too long to do any good. It only gets worse with miles.

This Mike Cowlishaw (Eagle Mfg & Engineering) solution is made from 17-4PH stainless steel, heat treated to 44c on the Rockwell scale. The alloy is characterized by great strength, it is also tough and not brittle (corrosion resistance is a side benefit). The material is more than twice as strong as the factory part. The one-piece billet design dramatically improves the strength over the OEM part. The design also increases the bearing surface (along the shaft) by about 100 percent in length. It also is reindexed to allow adjustment for the entire useful life of the chain.

Included in the Doohickey upgrade kit is: one balancer idler lever and NO SPRINGS as of 1/29/18. We prefer to use the Eagle Torsion spring kit which includes a 1/16" drill bit for creating an anchor for the stationary pin of the torsion spring. The torsion spring offers significant advantages over a conventional extension spring setup:

  • The Torsion Spring has enough adjustment range for the life of the engine;
  • The Torsion Spring is captured on installation;
  • The Torsion Spring takes the excess slack out of the system in the best possible way since it attaches directly to the adjustment lever.
  • The Torsion Spring is the only spring to use, the factory style extension springs have to be replaced after a period of time so why use them is our thought.
  • Do the job right with the Torsion Spring.

For a detailed printable doohickey installation guide click here. For higher resolution photos used in the installation guide please visit our installation site at http://happy-trail.smugmug.com.

 

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  • Do you still rent the doohickey tools? Can't find the option on the website.Thank you,Kirt
    Question by: Kirt Curell on 2019-01-31 22:28:00

    We don't rent tools anymore. We could not get the tools back in a reasonable amount of time. We lowered the price of our wrench to compensate for the rental.

    Answer by: Tim on 2019-01-31 17:28:00
  • Reading this, the "doo" comes with the torsion spring, correct? Also, I have a 2008, will this kit come with the "deep hole" spacer? Is it possible to only rent the tools vs. purchasing the whole kit (if the deep hole spacer isn't provided, I'll need to purchase the "doo" from Eagle Mike)? Thanks!
    Question by: David Hartley on 2018-06-25 18:39:00

    We don't provide the deep hole spacer as an option.

    Answer by: Tim on 2018-06-25 14:39:00
  • How do I know when the dohickey needs replaced?V
    Question by: Kevin on 2018-03-26 21:56:00

    HISTORICAL FACTS:

    Early KLR's maybe up to 95 had a welded Doohickey and that caused stress failures, the design of the spring is also flawed and has a shrt life cycle.

    First Doohickey Clinic we did in 2004 25 of 25 failed spec.

    08 & later have a new design Doohickey that does not fail, the spring has the same issues with a short life cycle.

    Eagle Mike Doohickey

    Has a diferent timing position of the Doohickey Lever which allows for at least 100k of adjustment.

    Torsion Spring has an infinite life cycle.

    You need to do it now with your 2011.

    Answer by: Tim on 2018-03-26 17:56:00
  • I was hoping to rent the tools for the doohickey, also I was going to get the gaskets but just in case my gaskets are still in good shape could I return them with the tools?
    Question by: DAVID A STECKEL on 2018-03-05 21:51:00

    The gaskets have to be perfect when we get them back so they can be resold to a customer. If you can do that there is no issue.

    The tools are used and that is the expecatation the customer has when he recieves them. 

    Answer by: Tim on 2018-03-05 16:51:00
  • Hi,I would like to order the part : KLR650 Doohickey (Balancer Idle Lever & Spring) All Years.Is it still available?And I would like it to be collected by DHL in your country.So, could you please provide an address they can pick it up please?Waiting for an answer from youKind regards
    Question by: Jitesh on 2017-03-30 01:41:00

    Happy Trails Products 

    7577 Lemhi St

    Boise Idaho 83709

    When you order you need to check local pickup. you can add a note with instructions authorizing a carrier to pick up the order.

    All doohickey parts are available.

    Answer by: Tim on 2017-03-29 21:41:00
  • Hi,I would like to know please how much it's worth to send the "KLR650 Doohickey" with its Torsion spring to Madagascar - Antananarivo. And after how many times I'll get it. Thanks for answering.Kind regardsKamlesh
    Question by: Kamlesh Mohanlal on 2016-09-20 01:18:00

    When you put your items in the shopping cart yuou can get a freight quote at that time.

    Answer by: Tim on 2016-09-19 21:18:00