Crank bearing wrong from Kawasaki
We are building a 820 kit for a guy in Maine cause his engine spun a bearing on the crank.
We got the engine in five boxes today and one look at it by Michael he knew what the problem was and it was not dirt getting by the air filter like Kawasaki said.
Before the guy shipped his engine he said he needed a new case cause his as some scarring on the inside of the case where the crank goes thru on the stator side.
The crank bearing retainer clips were not flat they were up at angle, the crank bearing was not all the way down in the case. We decided this would definitely cause the crank to get pushed over and rub on the case.
The crank had been pressed out by the dealership and at first we thought maybe when they pressed the crank out it tried to push the bearing out and bent the retainers. We also thought maybe the bearing pocket was not machined enough for the bearing to go all the way in.
So we put the case in the press and tried to press the bearing back in and it went down like it was supposed to. We then said well it still could have been pushed out when they pushed the crank out. I told Michael, if the screws are loose on the retainers now then they didn't push the bearing all the way in at Kawasaki and tightened the retainers against the bearing as is.
Guess what? The screws tightened on up with the bearing all the way in. Had they not tightened then that would mean the retainers were bent but they were not.
Ok, so what really caused his crank failure was the fact that his crank was pushed over to one side and the rods had a side load on them causing extra pressure on one side of the bearing. The bottom of the rods were blue from the heat too.
So after he got Kawasaki support back on the phone they told him that they it was the air filter and there was nothing wrong with the crank and actually hung on him.
I like the Teryx but Kawasaki themselves suck!!
The dealer that took this engine apart should have seen it too and they could have called Kawi and told them of there findings but they missed it. They tried to put the crank back in before they shipped it to me and mashed the speed sensor flat on their press and still didn't get the crank in.
Point is all dealers are not created equal and just cause they tell you one thing does not mean it is correct. This time he is going to have to spend a good bit of money to fix something Kawi screwed up at factory.
At least it will be right when it leaves here!!