Wilsons Sandbox

Posted: **Thu Mar 03, 2005 8:10 am**

Just took delivery of a new 05. I'm trying to get a handle on this doohicky thing. What is the failure rate? The mechanics at the dealer I bought it from are extremely reputable and have been at this particular dealer for years so I tend to believe they are not blowing smoke up my butt. After I bought the bike, I went and talked to the mechanics and they stated they never had a KLR come back for a failure. Now I'm not saying they haven't and can't fail but just what is the know percentage? I'm personally a pretty good mechanic but I'm adverse to taking apart a brand new machine for no reason. I have seen pic's of failures so certainly some fail for whatever reason? Looking at the way the adjust arm gouges, I'm inclined to think overtorqing the tensioner adjust bolt may start the failure? Just a theory looking at the pics. No doubt the aftermarket tensioner arm is a nicer part.

Posted: **Thu Mar 03, 2005 8:47 am**

Doohickey replacement has been the subject of some controversy on this board. They sometimes break, thats pretty clear from the photos and testimony. Why they break is another question. Exceeding redline? Prior misadjustment? Metal fatigue or bad welds?? I bought an A19 last November and joined the group but decided not to drink the Kool Aid if you know what I mean. The replacement procedure seems fraught with peril to all but expert mechanics. Brain surgery--not recommended for non-brainsurgeons but maybe straight forward if you happen to be one. -------------------------------------------------- --- In DSN_KLR650@yahoogroups.com, "greenmachine045" wrote:

> > Just took delivery of a new 05. I'm trying to get a handle on this > doohicky thing. What is the failure rate? The mechanics at the

dealer

> I bought it from are extremely reputable and have been at this > particular dealer for years so I tend to believe they are not

blowing

> smoke up my butt. After I bought the bike, I went and talked to

the

> mechanics and they stated they never had a KLR come back for a > failure. Now I'm not saying they haven't and can't fail but just

what

> is the know percentage? I'm personally a pretty good mechanic but

I'm

> adverse to taking apart a brand new machine for no reason. I have > seen pic's of failures so certainly some fail for whatever reason? > Looking at the way the adjust arm gouges, I'm inclined to think > overtorqing the tensioner adjust bolt may start the failure? Just

a

> theory looking at the pics. No doubt the aftermarket tensioner arm

is

> a nicer part.

Posted: **Thu Mar 03, 2005 8:58 am**

On Mar 3, 2005, at 8:09 AM, greenmachine045 wrote:

> Just took delivery of a new 05. I'm trying to get a handle on this > doohicky thing. What is the failure rate?

I've been involved in a couple of 'doo parties. The first, out of 4 bikes, one had a broken spring which we never found. The second, with 3 bikes, one doohicky was broken. So, from my limited experience, the "failure rate" is between 1 and 3 or 1 and 4. Age of bikes and mileages were all over the place from a couple thousand on newer bikes to 20K or so on older bikes.

> The mechanics at the dealer > I bought it from are extremely reputable and have been at this > particular dealer for years so I tend to believe they are not blowing > smoke up my butt. After I bought the bike, I went and talked to the > mechanics and they stated they never had a KLR come back for a > failure.

I'd be surprised if you ever find a dealership mechanic who HAS noticed a broken 'doo or spring; most never get in there to check. A KLR can go a long time with a broken 'doo or spring (assuming the lost parts don't trash the engine).

> I'm personally a pretty good mechanic but I'm > adverse to taking apart a brand new machine for no reason.

As was I. After changing my 'doo and spring, and helping several others, I wouldn't hesitate to change it on a brand new bike.

> I have > seen pic's of failures so certainly some fail for whatever reason? > Looking at the way the adjust arm gouges, I'm inclined to think > overtorqing the tensioner adjust bolt may start the failure? Just a > theory looking at the pics. No doubt the aftermarket tensioner arm is > a nicer part.

My bet is that; both the 'doo and spring material is just cheap, so it could be vibration that does them in, improper tightening or other various reasons. Sean Louisiana, A17

Posted: **Thu Mar 03, 2005 9:17 am**

The stock "DOO" is two pieces welded together. The metal is cheep and getting it hot enough to weld the two together causes them to be weeker, in my honest opion.

--- In DSN_KLR650@yahoogroups.com, Sean Smith wrote: > > On Mar 3, 2005, at 8:09 AM, greenmachine045 wrote: > > Just took delivery of a new 05. I'm trying to get a handle on this > > doohicky thing. What is the failure rate? > > > I've been involved in a couple of 'doo parties. The first, out of 4 > bikes, one had a broken spring which we never found. The second, with > 3 bikes, one doohicky was broken. So, from my limited experience, the > "failure rate" is between 1 and 3 or 1 and 4. Age of bikes and > mileages were all over the place from a couple thousand on newer bikes > to 20K or so on older bikes. > > > > The mechanics at the dealer > > I bought it from are extremely reputable and have been at this > > particular dealer for years so I tend to believe they are not blowing > > smoke up my butt. After I bought the bike, I went and talked to the > > mechanics and they stated they never had a KLR come back for a > > failure. > > > I'd be surprised if you ever find a dealership mechanic who HAS noticed > a broken 'doo or spring; most never get in there to check. A KLR can > go a long time with a broken 'doo or spring (assuming the lost parts > don't trash the engine). > > > I'm personally a pretty good mechanic but I'm > > adverse to taking apart a brand new machine for no reason. > > > As was I. After changing my 'doo and spring, and helping several > others, I wouldn't hesitate to change it on a brand new bike. > > > > I have > > seen pic's of failures so certainly some fail for whatever reason? > > Looking at the way the adjust arm gouges, I'm inclined to think > > overtorqing the tensioner adjust bolt may start the failure? Just a > > theory looking at the pics. No doubt the aftermarket tensioner arm is > > a nicer part. > > > My bet is that; both the 'doo and spring material is just cheap, so it > could be vibration that does them in, improper tightening or other > various reasons. > > > Sean > Louisiana, A17

Posted: **Thu Mar 03, 2005 9:42 am**

I felt the same way, that this was risky and perhaps left alone. I set up a "doohickey party" invite on line and was pleasantly surprised at the responses. The replacement job was a snap. 4 of us got together with skills ranging from fairly good to "don't even change my own oil". Universal success! All went away happy and confident and with 3 more KLR friends. By the way, all 4 factory parts were just fine but I have to agree that this part is a potential time bomb with disasterous results. The Risk/benefit ratio was quite favorable.

>From: "Joseph Jones" >To: DSN_KLR650@yahoogroups.com >Subject: [DSN_KLR650] Re: Doohickey Info >Date: Thu, 03 Mar 2005 15:16:47 -0000 > > > > >The stock "DOO" is two pieces welded together. The metal is cheep and >getting it hot enough to weld the two together causes them to be >weeker, in my honest opion. > > > >--- In DSN_KLR650@yahoogroups.com, Sean Smith wrote: > > > > On Mar 3, 2005, at 8:09 AM, greenmachine045 wrote: > > > Just took delivery of a new 05. I'm trying to get a handle on this > > > doohicky thing. What is the failure rate? > > > > > > I've been involved in a couple of 'doo parties. The first, out of >4 > > bikes, one had a broken spring which we never found. The second, >with > > 3 bikes, one doohicky was broken. So, from my limited experience, >the > > "failure rate" is between 1 and 3 or 1 and 4. Age of bikes and > > mileages were all over the place from a couple thousand on newer >bikes > > to 20K or so on older bikes. > > > > > > > The mechanics at the dealer > > > I bought it from are extremely reputable and have been at this > > > particular dealer for years so I tend to believe they are not >blowing > > > smoke up my butt. After I bought the bike, I went and talked to >the > > > mechanics and they stated they never had a KLR come back for a > > > failure. > > > > > > I'd be surprised if you ever find a dealership mechanic who HAS >noticed > > a broken 'doo or spring; most never get in there to check. A KLR >can > > go a long time with a broken 'doo or spring (assuming the lost >parts > > don't trash the engine). > > > > > I'm personally a pretty good mechanic but I'm > > > adverse to taking apart a brand new machine for no reason. > > > > > > As was I. After changing my 'doo and spring, and helping several > > others, I wouldn't hesitate to change it on a brand new bike. > > > > > > > I have > > > seen pic's of failures so certainly some fail for whatever reason? > > > Looking at the way the adjust arm gouges, I'm inclined to think > > > overtorqing the tensioner adjust bolt may start the failure? Just >a > > > theory looking at the pics. No doubt the aftermarket tensioner >arm is > > > a nicer part. > > > > > > My bet is that; both the 'doo and spring material is just cheap, so >it > > could be vibration that does them in, improper tightening or other > > various reasons. > > > > > > Sean > > Louisiana, A17 > > > > > >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 > > >Yahoo! Groups Links > > > > > > >

Posted: **Thu Mar 03, 2005 10:11 am**

First off, Welcome to KLRville.. Its up to you, its your ride. I looked at it as more "piece of mind" maintence related, and just did it for a few dollars it cost me. Now I know it will be fine. Period.. Its all in the rider, some ride there bikes basically on pavement all the time, some adventure on gravel and roads and some just ride the beast whereever they feel like going. Knowing something as simple as changing a little lever and spring keeps me from thinking about riding a grenade. All I am saying. Dooden A15 (Frozen)Green Ape --- In DSN_KLR650@yahoogroups.com, "greenmachine045" wrote:

> > Just took delivery of a new 05. I'm trying to get a handle on this > doohicky thing. What is the failure rate? The mechanics at the dealer > I bought it from are extremely reputable and have been at this > particular dealer for years so I tend to believe they are not blowing > smoke up my butt. After I bought the bike, I went and talked to the > mechanics and they stated they never had a KLR come back for a > failure. Now I'm not saying they haven't and can't fail but just what > is the know percentage? I'm personally a pretty good mechanic but I'm > adverse to taking apart a brand new machine for no reason. I have > seen pic's of failures so certainly some fail for whatever reason? > Looking at the way the adjust arm gouges, I'm inclined to think > overtorqing the tensioner adjust bolt may start the failure? Just a > theory looking at the pics. No doubt the aftermarket tensioner arm is > a nicer part.

Posted: **Thu Mar 03, 2005 10:59 am**

Something that probably accounts for overtightening: page 72 of the owner's manual that came with my '04, reference the balancer chain, says... REMOVE THE TENSIONER CAP AND LOOSEN THE TENSIONER BOLT A FEW TURNS. TIGHTEN BACK THE BOLT AND INSTALL THE CAP IN THE ORIGINAL POSITION. Wow - isn't that ever SPECIFIC!!! No mention of torque requirements, how much ... a FEW turns ... is, etc, etc. No wonder those delicate little pieces get damaged, even by conscientious owners trying to do their best! My .02$ Ed --- In DSN_KLR650@yahoogroups.com, "greenmachine045" wrote:

> > Just took delivery of a new 05. I'm trying to get a handle on this > doohicky thing. What is the failure rate? The mechanics at the dealer > I bought it from are extremely reputable and have been at this > particular dealer for years so I tend to believe they are not blowing > smoke up my butt. After I bought the bike, I went and talked to the > mechanics and they stated they never had a KLR come back for a > failure. Now I'm not saying they haven't and can't fail but just what > is the know percentage? I'm personally a pretty good mechanic but I'm > adverse to taking apart a brand new machine for no reason. I have > seen pic's of failures so certainly some fail for whatever reason? > Looking at the way the adjust arm gouges, I'm inclined to think > overtorqing the tensioner adjust bolt may start the failure? Just a > theory looking at the pics. No doubt the aftermarket tensioner arm is > a nicer part.

Posted: **Thu Mar 03, 2005 12:46 pm**

Anyone who's seen a stock doohickey up close and personal wouldn't hesitate to change it out. It's a pretty cheesey part; my feeling is that they got cheesier over the years.I think you're right about improper torque not helping the situation. My A1 went 40k miles with no problems. My A11 had an intact, but tacky-looking doohickey at 16k miles. Does anyone have the model years available from the various failures? A nice histogram of failures/model year would be instructive. __Arden --- In DSN_KLR650@yahoogroups.com, "greenmachine045" wrote:

> > Just took delivery of a new 05. I'm trying to get a handle on this > doohicky thing. What is the failure rate? The mechanics at the

dealer

> I bought it from are extremely reputable and have been at this > particular dealer for years so I tend to believe they are not

blowing

> smoke up my butt. After I bought the bike, I went and talked to the > mechanics and they stated they never had a KLR come back for a > failure. Now I'm not saying they haven't and can't fail but just

what

> is the know percentage? I'm personally a pretty good mechanic but

I'm

> adverse to taking apart a brand new machine for no reason. I have > seen pic's of failures so certainly some fail for whatever reason? > Looking at the way the adjust arm gouges, I'm inclined to think > overtorqing the tensioner adjust bolt may start the failure? Just a > theory looking at the pics. No doubt the aftermarket tensioner arm

is

> a nicer part.

Posted: **Thu Mar 03, 2005 1:02 pm**

--- In DSN_KLR650@yahoogroups.com, "greenmachine045" wrote:

> > > Looking at the way the adjust arm gouges, I'm inclined to think > overtorqing the tensioner adjust bolt may start the failure? Just a > theory looking at the pics.

See the link and excerpt below by Jim Hyman. http://www.bigcee.com/balancer.html "DON'T use a 3/8" ratchet for the adjuster bolt. A 1/4" ratchet or extension bar will give you a much better feel. Tighten the bolt to finger tight and then tighten 1/8 of a turn further. This will give you the proper 52 - 69 INCH-pounds of torque (i.e. 4 - 6 FOOT- pounds)." Jim A17

Posted: **Thu Mar 03, 2005 3:12 pm**

Congrats on the 05! Regarding the Doohickey. I had the same reaction as you have. So just for fun I also asked the dealer about it and their response was the same. No problems. I even told them it would not deter me from buying the bike. I also asked them that if I decided to have it changed during the first service, and had them do it, would they still cover the bike under warrantee unless it was the replacement part that caused a problem. They said YES they would cover everything except the part if they did the install (they want the labor money). Obviously a dealer could try claiming an aftermarket part caused a failure but since the bike is basically bullet proof I suspect the warrantee would run out before that became an issue. Ultimately I decided to wait until the warrantee is up. If I start racking up the miles then I may change it sooner. Jon...

Wilsons Sandbox

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