starter idler gear bushing worn at one side.
 

Has anyone come across this before?
Took the cover off to change the stator and noticed it worn almost through.

https://www.kawasakiforums.com/forum...-1259-4188.jpg

https://www.kawasakiforums.com/forum...-1258-4187.jpg

https://www.kawasakiforums.com/forum...-1261-4189.jpg

This is not the first time we have seen this, but at least it looks like you caught it before it trashed the case.


https://www.kawasakiforums.com/forum...e-cases-39378/

I don't believe anyone knows why this happens. Dan (the op from thread above) thought it was a detonation problem (engine trying to run backwards) but almost seems like just a random bad bushing issue.

I had my cover off the other day swapping flywheels and didn't see any abnormal wear on mine luckily.

My bike has only done 8000 KM. Yes, no real damage to the case thank F--k Does anyone have any recommendations for a bushing material while i wait for the new ones from the states/ ?
I have access to a lathe. I assume brass will be a bit soft ?

Thanks again guys for all your input.
George

I think brewster made one for his out of oil impregnated bronze. I would think it would work, at least temporarily -

https://www.kawasakiforums.com/forum...42/#post535498

*EDIT* looks like durielk had one made of brass bushing stock (post #2 in same thread above) maybe he will chime in as to whether or not its still holding up.

Yea, the wrench @ the LMS had his machinist brother make a new bushing out of bushing material (it looks like brass), still working great.
I used to stall the moto a lot, really a lot, and it always died with a big clunk, & am thinking that damage was happening at the stalls cause I always heard a big clunk. Might have been the ACR though, after fixing I don't think about it much.

I replaced the bushing in the idler gear. Looks like you have a different problem.
This is what I used to machine a replacement but can't verify if it will hold up as I haven't put many miles on the bike since making it.

https://www.mcmaster.com/#flanged-sl...rings/=183emgk

Ride on
Brewster

Thanks Brewster,
I will have to use brass stock until my kawasaki parts come.
How tight did you make it ?
The bush in the alternator cover is also very slack although still round.
I would have assumed it to be a perfect engineering fit.
Any help would be grateful.

I was shooting for 0.002" clearance.
On my KLX300, the shaft diameter is 17mm = 0.66929"
I made the ID of the bushing 17.05mm = 0.67126"
I found the McMasterCarr p/n 2938T18 that I machined down.

I can't tell from my scribbling notes what the interference fit was between the bushing and bore of the idler gear.

Ride on
Brewster

If you find one of those mcmaster flanged bearings to fit (you may have to cut off the flange?), post the one that works here for others. That would be easier than going to a machinist.
My issue was similar to as posted, on the outside of the left engine case.

A flange remains.
I'm lucky enough to have a bench top lathe in my garage to do small and easy projects like this. Please don't ask me to make one as I'm not SURE that it would hold up. Check with a machinist as to what the correct material should be for this application.

Ride on
Brewster