For Kawasaki KLR650 owners, the term Eagle Mike Doohickey is almost legendary. This small but vital part plays an essential role in maintaining the reliability and performance of the motorcycle’s engine. The doohickey, formally known as the balancer chain tensioner lever, helps keep the engine’s balancer system properly adjusted. Installing the Eagle Mike Doohickey upgrade has become a rite of passage for many KLR riders who want to improve their bike’s longevity, smoothness, and mechanical soundness. Understanding how to perform the Eagle Mike Doohickey install is crucial for anyone looking to get the best out of their KLR650.
What Is the Doohickey?
The doohickey is a nickname given by KLR riders to the balancer chain tensioner lever in the engine of the Kawasaki KLR650. Its function is to maintain proper tension on the counterbalancer chain, which reduces engine vibration and ensures smooth operation. However, the stock doohickey in older KLR models especially those produced before 2008 has been known to fail due to poor materials and weak springs. When this part breaks or becomes ineffective, it can cause rattling noises, poor balance, and in severe cases, internal engine damage.
That’s where Eagle Mike comes in. Eagle Mike is a well-known manufacturer in the KLR community who designed a high-quality replacement for the factory doohickey. His version is made from stronger materials and comes with an improved torsion spring for precise tension adjustment. Installing the Eagle Mike Doohickey ensures that the balancer system operates as it should, improving the engine’s smoothness and reliability over time.
Why Upgrade the Doohickey?
Upgrading to the Eagle Mike Doohickey is considered one of the most important maintenance steps for KLR owners. Even newer models, while improved, can still benefit from this upgrade. The reasons for replacing the stock doohickey are both preventive and performance-related.
- DurabilityThe stock lever and spring may crack, stretch, or fail over time, leading to potential engine imbalance.
- PrecisionThe Eagle Mike version provides smoother and more accurate tension control, reducing vibration during rides.
- LongevityThe upgraded part extends the engine’s life by keeping the balancer chain properly adjusted.
- Peace of MindOnce installed, riders don’t have to worry about one of the most common KLR mechanical weaknesses.
Preparing for the Installation
Before beginning the Eagle Mike Doohickey install, it’s essential to have the correct tools and workspace ready. You will need a few special tools in addition to standard motorcycle maintenance equipment. Eagle Mike offers a doohickey installation kit that includes the tools required for the job.
Tools and Materials Needed
- Eagle Mike Doohickey kit (includes lever and torsion spring)
- Rotor puller tool
- Flywheel holder wrench
- Socket wrench set
- Torque wrench
- Drain pan and rags
- New gasket (optional but recommended)
- Fresh engine oil (if performing an oil change simultaneously)
Before starting, ensure the motorcycle is on a stable stand and the engine is cool. Disconnect the battery and drain the engine oil to avoid spills when removing the side cover. Patience and attention to detail are key throughout the installation process.
Step-by-Step Doohickey Installation
The installation involves accessing the left side of the engine, removing the cover, replacing the old tensioner lever and spring, and reinstalling all components carefully. Below is a general outline of the process.
1. Remove Engine Components
Start by removing the skid plate (if installed), footpeg bracket, and the left engine cover. Make sure to collect all bolts and note their placement. Drain the oil completely to prevent mess. Once the cover is removed, you will see the flywheel and the balancer lever assembly.
2. Remove the Rotor (Flywheel)
Use the rotor puller tool and flywheel holder to safely remove the rotor. This step may require some force, so be cautious not to damage the crankshaft threads. Once removed, the balancer lever and spring will be visible.
3. Remove the Stock Doohickey
Inspect the stock doohickey lever and spring. Many riders are surprised to find that the spring has lost tension or the lever has visible wear. Carefully remove both parts. Clean the area thoroughly to remove old debris and oil residue.
4. Install the Eagle Mike Doohickey
Install the new Eagle Mike lever in the same position as the original. Attach the torsion spring according to the instructions provided in the kit. The torsion spring design offers a more reliable and consistent pull than the original extension spring. Ensure that the spring is seated correctly and provides sufficient tension.
5. Reassemble the Engine Components
Once the new lever and spring are installed, reinstall the rotor and torque the bolt to the manufacturer’s specification. Replace the engine cover using a new gasket if necessary. Reinstall the footpeg bracket and skid plate. Finally, refill the engine oil and reconnect the battery.
Testing and Adjustment
After completing the Eagle Mike Doohickey install, it’s important to test the system to ensure everything is functioning properly. Start the engine and listen for any unusual noises. The engine should sound smoother and exhibit reduced vibration, especially at idle and mid-range RPMs. Take the motorcycle for a short ride and observe how it feels most riders notice immediate improvements in balance and smoothness.
Some mechanics recommend rechecking the doohickey tension after several hundred miles, especially on older engines. However, once installed correctly, the Eagle Mike Doohickey requires minimal maintenance and can last for the lifetime of the motorcycle.
Common Mistakes to Avoid
While the installation is straightforward for someone with mechanical experience, beginners should watch for common pitfalls that could cause issues later.
- Forgetting to drain oilThis can cause a big mess when removing the engine cover.
- Overtightening boltsUsing too much torque on the rotor bolt or cover screws can damage threads.
- Incorrect spring placementThe torsion spring must be installed precisely; otherwise, it won’t maintain tension properly.
- Not using proper toolsAttempting to remove the rotor without the correct tools can cause serious engine damage.
Benefits After Installation
After completing the Eagle Mike Doohickey installation, most KLR650 riders experience a noticeable difference in engine behavior. Vibrations are reduced, the idle becomes steadier, and overall performance feels smoother. Long-distance riders particularly appreciate the upgrade because it provides peace of mind during extended trips through remote areas. With the stronger lever and improved spring design, the engine’s balance system can now function exactly as it was meant to.
Long-Term Impact on the KLR650
The Eagle Mike Doohickey is often considered a one-time investment that pays off for years. Many riders who upgrade early in their KLR’s life report reaching high mileage with fewer mechanical problems. The modification also prevents potential engine failures that could arise from a broken or weak stock component. Whether you use your KLR for commuting, adventure touring, or off-road exploration, this small but essential part makes a big difference in reliability.
The Eagle Mike Doohickey install is more than just a mechanical upgrade it’s a safeguard for the KLR650’s heart. While the process requires patience and the right tools, the result is a more stable, reliable, and smoother-running motorcycle. For many enthusiasts, performing the installation is a badge of honor that connects them to the long tradition of KLR riders who take pride in maintaining their machines. By replacing the flawed factory part with a precision-engineered component, you’re ensuring that your engine runs confidently for thousands of miles to come. The doohickey upgrade is, without a doubt, one of the smartest and most rewarding modifications any KLR owner can make.