KLX Idler Gear Replacement
The results of NOT replacing the idler gear are... BAD!
|CLICK TO ENLARGE|
Here are Stroker's Instructions. We thought we could do better.
"Special" tools: snap ring plyers
Supplies: Clutch cover gasket and blue loctite
|1. Remove 6 bolts on clutch cover. Draining oil is not necessary. You don't need to remove clutch cable, simply flip up and rest on header.|
|2. Remove clutch release plate and pin.|
|3. Put bike in idler-. Remove clutch hub nut. Remove clutch assembly.|
|4. Remove snap ring and old idler idler-. You will need to keep the THIN outside washer. The THICK inside washer will be replaced by the supplied THIN washer.|
|4A. Here is sample of THIN and THICK inside washers.|
|4B. Old and New Idler Gear|
|5. Install new idler-: Sequence is THIN washer, Idler idler-, THIN washer, and snap ring. Be sure snap ring is seated in groove.|
|6. These are the parts you should have left:
(1)One stock Idler idler- and (1)One THICK washer.
|7. Install clutch hub assembly. Torque clutch hub nut to 58 ft-lbs. Install new gasket, and cover. Torque clutch cover bolts to 87 in-lbs.|