imported post
imported post
Check this out.
http://multisurfacemotorcycling.com/klr650_page.htm#Known%20Issues
http://www.klr650.marknet.us/balancer.html
Balancer chain tensioner ("Doohickey") prone to failure
The counterbalancer tensioner arm (clamped down by the small bolt on the bottom left engine cover) has a tendency to get brittle and break. This has happened on bikes of all years and mileages, while many other bikes (of all years and mileages) are fine. If anything, later bikes seem to be more prone to failure, perhaps because of the change to solid balancer sprockets. If this system fails and the balancer chain jumps, it can sieze the engine.
Eagle Machine makes a machined adjuster arm (available from Arrowhead) that is vastly superior to the stock unit. (Both units are of equal quality, although they offer different spring lengths.) In addition, the adjuster bolt and spring were upgraded in 1996; earlier models can be upgraded by replacing the bolt and spring, and adding the washer. The required parts are: Idler spring, 92144-1860; 7mm O-ring, 670B1507; washer, 92200-1263; idler adjuster bolt, 92150-1923. See the
links section for a way to report balancer failures.