starter idler gear bushing worn at one side.
#2
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.
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.
#3
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 have access to a lathe. I assume brass will be a bit soft ?
Thanks again guys for all your input.
George
#4
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 have access to a lathe. I assume brass will be a bit soft ?
Thanks again guys for all your input.
George
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.
Last edited by wildcard; 06-16-2017 at 12:28 PM.
#5
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 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.
#6
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
Last edited by Brewster; 06-16-2017 at 02:33 PM.
#7
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 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.
#8
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
#9
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.
My issue was similar to as posted, on the outside of the left engine case.
#10
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