Question about 2001 kawasaki KLX 300
Are you sure you put them back together in the correct sequence and spacings? To me it sounds as you missed something such as over tightneing or wrong clutch sequence. Try re-do it again.
Posted on Apr 26, 2010
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Posted on Jan 02, 2017
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To get to the kick starter shaft and idler gear you will first have to remove the kick start and brake levers. Then remove the water pump cover and circlip, the impellor, and steel drive pin. Then remove all side cover bolts and pull the cover off the engine. Don,t let the water pump shaft come out of the engine when you pull of the cover . Suggest the best thing to do is set the engine in TDC with the timing marks on the cam side together. When the shaft come out you have to time it again, so hold it in place in the engine.
Hold WP shaft down with your thumb while pulling on the cover.
Once the cover is off the Kick Start idler gear assembly lifts out easy but as you put it together there is a center punch mark on the gear that goes in first that MUST be in aline with the spring hole drilled into the shaft, if not in aline the starter will engage at the wrong point.
Reinstall new shaft and idler gear in reverse order.
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