Doohickey problems!
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Author Topic: Doohickey problems!  (Read 3182 times)
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silveralt
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« on: June 02, 2011, 12:56:30 PM »

I just got a 1990 KLR 650. I love the bike! I have done tons of work to it and saved the doohickey for last. The bike has 22k miles on it and the doo and spring were both perfect! I replaced it anyway. Well now I have a small leak coming fom the doohickey adjuster hole on the case. I took it apart again and replaced the o ring on the shaft. The old one wasn't in the best shape. I thought I fixed it... But the leak is back!!! Has anyone ever run into this? The leak doesn't appear to be coming from the seal between cases. I'm completely lost!

Here's a pic of the bike!

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rustynut
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« Reply #1 on: June 02, 2011, 01:23:20 PM »

I remember a washer going on the EM doo/adjuster after replacement. Without the washer the oring doesn't seal to the case do to the difference in the thickness of the parts. My bike is an 09 if that makes a diff.
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silveralt
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« Reply #2 on: June 02, 2011, 01:27:04 PM »

Yeah. I made sure that was in there too! I'm at a loss 
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PonchoV
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« Reply #3 on: June 02, 2011, 01:49:19 PM »

Did any part of the paper gasket seperate, break...,?
Was the cove hole for the tention bolt clean of sand or grit?

The tention adjustment bolt wasn't bent...?

Just trying to think of the little things frist.
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silveralt
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« Reply #4 on: June 02, 2011, 01:54:10 PM »

Appreciate the questions.. No sand or grit. Looked straight to the eye. Someone on another forum suggested it was torqued a little too much.. And I might have made it a little too tight. I'm using a Harbor Freight torque wrench. So I will try backing the bolt out just a hair.
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PonchoV
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« Reply #5 on: June 02, 2011, 02:20:05 PM »

We had a member recently torque the same bolt & it resulted in a bit of a problem.
Please tell us what was your specs for the troque setting.
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gunny
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« Reply #6 on: June 02, 2011, 04:36:36 PM »

"if" you left the washer out from between the adjuster and the doo, it might let it sit far enough "in" that the o-ring isn't making good contact.
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chinkymo
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« Reply #7 on: June 02, 2011, 08:45:41 PM »

We had a member recently torque the same bolt & it resulted in a bit of a problem.
Please tell us what was your specs for the troque setting.

Who might that be?????  Hmmmmm... LOL! 69 inch pounds, not foot pounds!  HMMMMM.....
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PonchoV
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« Reply #8 on: June 02, 2011, 08:50:48 PM »

Hey, I'll NEVER tell. poke

Everything back to normal?
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chinkymo
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« Reply #9 on: June 02, 2011, 10:06:21 PM »

Hey, I'll NEVER tell. poke

Everything back to normal?

Right as rain  I'm cruizin' Dodged a bullet with that one. Things could have ended much worse for me. 
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rustynut
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« Reply #10 on: June 03, 2011, 05:54:59 AM »

still laughing over here, poor little doo  Too funny!
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PonchoV
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« Reply #11 on: June 03, 2011, 05:55:34 AM »

There's a lot of us here who still manage to keep driving that very same Dodged bullet........... WTF?

Now you've earned your position as, "wait check that torque setting" soapbox

We all need reminding.
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silveralt
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« Reply #12 on: June 03, 2011, 01:47:41 PM »

I fixed the oil leak. The hole for the adjuster bolt needed to be filed down a little so it was even for the seal to work properly.


Glad I got that out of the way!
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PonchoV
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« Reply #13 on: June 03, 2011, 01:53:51 PM »

What was in the way?

Was the case to thick or rough casting left behind.....Pix?

Glad you got it & told us.

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