CAM CHAIN ADJUSTER OTHERWISE KNOW AS A DOOHICKEY. IF IT FAILS IT MAY CAUSE THE ENGINE TO SEIZE UP WITHOUT WARNING, I CHANGE MINE AFTER IT BROKE BUT DID NOT CAUSE MASSIVE INTERNAL DAMAGE I WAS UNAWARE THAT MINE HAD FAILED I DID THE CHANGE AS PREVENTATIVE MAINTENANCE THIS PROBLEM HAS BEEN KNOWN TO THE KLR COMMUNITY FOR MANY YEARS BUT KAWASAKI REFUSES TO RECOGNIZE IT, DO A GOOGLE SEARCH ON DOOHICKEY FOR MORE INFO
No injuries · No fire · No crash
THE IDLER SHAFT LEVER (AKA "DOOHICKEY") BROKE IN HALF AND THE PIECES OF IT WERE FLOATING AROUND IN THE CRANK CASED. THIS IS VERY DANGEROUS BECAUSE IF A PIECE OF THE IDLER SHAFT LEVER GETS CAUGHT IN THE COUNTERBALANCE CHAIN OR CAUSES A CRANK BEARING FAILURE THE ENGINE COULD LOCK UP AT SPEED CAUSING A CRASH. I REPLACED THE IDLER SHAFT LEVER WITH A STRONGER AFTERMARKET COMPONENT. *TR
No injuries · No fire · No crash
THE IDLE SHAFT LEVER IN MY 2001 KAWASAKI KLR650 HAD COMPLETELY BROKEN INTO 2 PIECES. I DISCOVERED THIS WHEN UPGRADING THE PART. IT COULD HAVE CAUSED CATASTROPHIC ENGINE FAILURE. *TR
No injuries · No fire · No crash
AFTER 14,000 MILES OF USE I AM THE SECOND OWNER OF THE MOTORCYCLE THE IDLE SHAFT LEVER FAILED. WITH THE FREQUENCY OF THIS FAILURE BEING REPORTED, THERE SHOULD BE A TSB ISSUED. *TR
No injuries · No fire · No crash
WHEN I TORE INTO MY 2001 KLR 650 TO INSPECT AND REPLACE THE FAULTY "DOOHICKEY". I FOUND THE FACTORY ONE BROKE. BOTH THE SPRING AND BALANCER WERE BROKE AND I DID NOT FIND EITHER PART IN THE MOTOR. THEY ARE STILL FLOATING AROUND IN THE MOTOR SOMEWHERE. THERE WAS SCARING ON THE PARTS INSIDE THE MOTOR WHERE YOU COULD TELL IT HAD HUNG UP ON OTHER MOVING PARTS AND LUCKILY DID NOT LOCK UP THE MOTOR. I REPLACED THE "DOOHICKEY" WITH AN AFTERMARKET BETTER PRODUCT AND HOPE THE LOOSE PIECES DO NOT FLOAT INTO MOVING PARTS TO TEAR UP MY MOTOR. *JB
No injuries · No fire · No crash