Has anyone had trouble with the idler gear going out on their KLX 300 and then having major engine problems from that? If so where can you find the aftermarket idler gear to replace the stock one?

 

Oh yeah [:'(]If you didn't get every fragment out...it is only a matter of time before the engine goes ka-blewey.

More likely than not if you broke a tooth you did other damage as well. In my case the shaft broke just inside the tranny side...that took out second gear and broke the race for the bearing...thetooth of the idler also got behind the clutch basket ruining the primary gear on the clutch. Note all this happened on one kick that went about half way down...thank goodness it didn't fire.

Do a search over on Thumpertalk and you'll find lots of articles on the idler and on re-timing the ACT...which is a must.

 

I noticed that my kick starter was getting sloppy and slipping sometimes. Then I heard an irregular rattling comming from the lower engine. I checked it out and the sleve in the gear was wore out, sothe gearwas rattling around and knocking on the back side of the clutch plate cover. Luckily I caught it beforethe gearthrew itself apart and totally blew the engine. Now I'm having a mechanic friend get me a aftermarket gear that I havn't been able to find online as described in otherwebsites.Hopefully it will work out.

 

The aftermarket gear didn't pan out because the comany that made them folded, so I had to gowith a stock replacement.