I fitted a new balance shaft chain tensioner mechanism the other day, know as the DooHickey in KLR circles. It’s a known weak point in the engine design of what is otherwise a generally unburstable motor. Later models like mine aren’t so bad, but it’s still worth doing if you’re planning a long trip. For peace of mind, it’s essential!
You need to remove the primary outer cover, rotor and primary inner. Special tools are required for this. The primary inner needs a hole drilling for the replacement torsion spring, then it all goes back together with new gaskets. Saying all this makes it sound very complex, but it’s actually quite simple.
The Original parts were holding up OK, but the motor is a lot quieter now. Surprisingly so. I also fitted a different bash plate, I much prefer this item. Another little job done in preparation for the trip!