Started the 840 kit today - Kawasaki Teryx Forums: Kawasaki UTV Teryx Forum
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post #1 of 70 (permalink) Old 02-18-2009, 09:12 PM Thread Starter
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Started the 840 kit today

Time consuming!! Remember.... I am an ignorant ass that knows nothing mechanical.
After 6 hours..yes 6 hours this is what I've got....
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post #2 of 70 (permalink) Old 02-18-2009, 09:14 PM Thread Starter
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and 20 minutes after that...this is what I got.....more to be continued....
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post #3 of 70 (permalink) Old 02-18-2009, 09:50 PM
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Six hours of bending over working on these things in the car would kill my fat as,that's why I only do motors on the bench.

Your parts are boxed up waiting for your stuff to get here!
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post #4 of 70 (permalink) Old 02-18-2009, 10:26 PM Thread Starter
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Got me camera waiting...hope to show everybody what a great kit it is!
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post #5 of 70 (permalink) Old 02-19-2009, 06:45 AM
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Hey... as long as you have the "support" liquid pain killer for after all the bending you are doing fine. The rest is easy except for installing the new valve springs and timing the cams. First time you drive your machine, your sore back is gonna celebrate with you.

2011 Teryx Sport
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post #6 of 70 (permalink) Old 02-19-2009, 10:22 AM
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It's not a bad thing to take your time and double check everything. I finished putting mine back together, but will finish welding my new cage before cranking it up and breaking it in. If you add the breather fitting in the rear head make sure it will clear the carb linkage cover.

'08 Teryx- Dyna CDI & Coils, HW Jet kit w/ TPI valves, Dalton clutch & OD plate, HID's, Muzzy's, FST 840, UNI, 4 Seat Cage, WER Shocks, 27" Bighorns & 29.5 Outlaws
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post #7 of 70 (permalink) Old 03-04-2009, 05:06 PM Thread Starter
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Finally got started back on my kit today, tell me something....what is the trick to getting the cam chains back on the cam sprocket, tried for about 40 minutes today, no luck....I am kinda thinking it is harder with the 840 kit, because the head gasket does appear to be thicker....any help out there for this dumbass....
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post #8 of 70 (permalink) Old 03-04-2009, 09:31 PM
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Are the tensioners removed? If so, may check for a kink or just keep trying as it doesn't just fall together easily. Mine has been back together for awhile, but haven't had the time to crank it.

'08 Teryx- Dyna CDI & Coils, HW Jet kit w/ TPI valves, Dalton clutch & OD plate, HID's, Muzzy's, FST 840, UNI, 4 Seat Cage, WER Shocks, 27" Bighorns & 29.5 Outlaws
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post #9 of 70 (permalink) Old 03-04-2009, 10:12 PM Thread Starter
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No, cam tension is not on motor yet. I think I am going to remove cam sprocket...add chain and then put sprocket back on cam (if possible), going to fiddle with it all day tomorrow, so HOPEFULLY will have some sense of what is going on, I'm doing the rear head first, then start on front.
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post #10 of 70 (permalink) Old 03-06-2009, 02:24 PM Thread Starter
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Well, I could not get cam chains back on...without removing the cam sprockets. You want to talk about a PITA, worse part was lining up timiming by the sprockets....removing and put back on....removing and put back on....removing....move the chain a tooth...put back on......ie...ie....have you gathered by now that I was at my wit's end. I had Kawa service, 2 different ones, tell me that I should have had 1/16 to 1/4 clearance on my chains and that they should have easily went back on, gaurantee...., for me, they don't and they didn't and.....NO.....my chains weren't off of the bottom sprockets.
I can remember when I took the stock cams out...it was the same way....very...very tight, and yes my tensioner was removed. Now that I have got it all back together....the cams look like they are in the same exact position as were the stock cams....meaning they look "seated" just like my stock cams were...in their bearings...so I know it has got to be right, getting ready to put valve heads back on.....not till tommorow...gotta rest....and not going to be thinking about my soon to be running monster.....maybe not till Monday...in fact.....I...at this moment do not care about "the satisfaction of doing this myself." Something on this magnitude was not for me...but I am going thru with it to the end.... next learning phase for me will be valve clearance 101...... I'll get there......
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