Transmission Noise - Kawasaki Teryx Forum
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post #1 of 28 (permalink) Old 09-04-2009, 02:26 PM Thread Starter
 
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Transmission Noise

OK here is the deal, I let my friend drive around a bit and he got high centered going down a hill, put into reverse to try and back out and the belt started slipping(it was on its way out anyways) so I said no big deal. Used a highlift to get it unstuck and thought all was good. Well I hop in it and go to move and its fine up to 5mph then it starts making a horrible noise almost like a pop but more metal on metal sounding. We get it home, and besides the noise and some minor belt slipping it drove fine. I put it up in the air thinking it is a CV going out pulled it all apart and checked everything the joints are fine. so we started tearing into it. we take the side of the case off and find that the noise is coming from the transmission area of the case, what could this be I may end up taking it back to the dealer but the last time I went to have my carbs tuned they charged me 150$ for 3 hours labor and nothing was changed so I am kind of leary to do that.
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post #2 of 28 (permalink) Old 09-04-2009, 02:40 PM
 
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a ton of teryx have had problems out of the gears in the transmission kawi left a washer out of the tranny on mine causiing the gears to have to much slack
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post #3 of 28 (permalink) Old 09-04-2009, 08:54 PM
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Its the belt, you spun an indention in the belt. I did the samething, terrible sound.
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post #4 of 28 (permalink) Old 09-05-2009, 10:02 AM
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check your shifter adjustment thats what was wrong with my buddy's.

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post #5 of 28 (permalink) Old 09-05-2009, 01:57 PM
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I agree with flat spot on the belt, smoked mine and made a horrible noise, it makes a hard spot on the belt, time for a new belt.
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post #6 of 28 (permalink) Old 09-05-2009, 02:44 PM
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I'm with Racer76, check linkage, when in a tight spot and the shifter does not move you can bend the bracket at the end of the rod at the engine. unless you "rock" the rex to free the gear to gear, this is a common mistake.

08 LE,Ceramic coated Muzzy's,840 FST kit W/Port work,YFZ catch can,EPI clutch mod, OD Cap,hw jet kit,UNI Filter,TPI's,std Dyna cdi,SS112's,BigHorn 2.0's. If it's stock it sucks
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post #7 of 28 (permalink) Old 09-20-2009, 08:24 PM
 
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Just came back from a ride this weekend. Mine is making a sound in the trans also. I believe that it is coming from the bevel gear in the engine, because it will do it in low and high, but not rev. It is only making noise on the pulling side of the gears. They may need to be reset. Tomorrow I will pull the gears out to see. Pulling these gears out is a small job. I will post my findings tomorrow.
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post #8 of 28 (permalink) Old 09-21-2009, 03:02 PM
 
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Just took the bevel gear out the engine. The pinion has failed with chips broken off of it. I am running 30" Silverbacks on mine. That is another problem, but man that thing will go!!!!!!!
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post #9 of 28 (permalink) Old 09-21-2009, 04:26 PM
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Quote:
Originally Posted by Luke "Dobber" Veillo View Post
Just took the bevel gear out the engine. The pinion has failed with chips broken off of it. I am running 30" Silverbacks on mine. That is another problem, but man that thing will go!!!!!!!
Can you post some pictures?
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post #10 of 28 (permalink) Old 09-21-2009, 05:28 PM
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Pulling the gears out is a small Job?? pics please

08 LE,Ceramic coated Muzzy's,840 FST kit W/Port work,YFZ catch can,EPI clutch mod, OD Cap,hw jet kit,UNI Filter,TPI's,std Dyna cdi,SS112's,BigHorn 2.0's. If it's stock it sucks
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post #11 of 28 (permalink) Old 09-21-2009, 05:33 PM
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Quote:
Originally Posted by SRX View Post
I'm with Racer76, check linkage, when in a tight spot and the shifter does not move you can bend the bracket at the end of the rod at the engine. unless you "rock" the rex to free the gear to gear, this is a common mistake.
This happened to me in Low Gear 4W. I was stranded in 2 feet of mud about a mile from home and all alone.. The shift lever would not budge and to top it off I turn the motor off. It wont start in gear. Something told me try rocking the Teryx back and forth, so I sat on the front bumper and rocked her good. It worked the linkage broke free. Needless to say, I no longer park in low gear.
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post #12 of 28 (permalink) Old 09-21-2009, 05:45 PM
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Originally Posted by AXO View Post
This happened to me in Low Gear 4W. I was stranded in 2 feet of mud about a mile from home and all alone.. The shift lever would not budge and to top it off I turn the motor off. It wont start in gear. Something told me try rocking the Teryx back and forth, so I sat on the front bumper and rocked her good. It worked the linkage broke free. Needless to say, I no longer park in low gear.
step on the brake it will start in gear.
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post #13 of 28 (permalink) Old 09-21-2009, 06:14 PM
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step on the brake it will start in gear.
No shit, that will save on some frustration when in a jam and can't shift! Thanks for the info

08 LE,Ceramic coated Muzzy's,840 FST kit W/Port work,YFZ catch can,EPI clutch mod, OD Cap,hw jet kit,UNI Filter,TPI's,std Dyna cdi,SS112's,BigHorn 2.0's. If it's stock it sucks
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post #14 of 28 (permalink) Old 09-21-2009, 07:45 PM
 
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The bevel gear are the only gears that can be retreived without pulling the engine. The trans gears requires pulling the engine. To remove the the bevel gears, remove bottom side plate, and drive shaft on the front and the rear. The rear has a snap ring that has to be removed. Push the shafts together, and they can both be moved. Engine oil must be drained, then remove the four bolts on the back of the engine that hold the shaft that goes though the engine. Pull it out from the rear. The bevel gear will be on the shaft, and the pinion will be right inside of the engine. The pinion can be inspected without removal. If bad then the pinion can be removed by taking off the cover where the dip stick is. Remove the drive gear (I beleive a snap ring holds it in place) Then remove the four bolts that hold the pinion. I have a repair manuel from Kawasaki that tells how to remove the bearing from the gears. The bevel gear requires a special Socket. I made one with a peice of pipe and a welding machine. O and by the way, I your looking to increase top end, use Brute Force bevel gear and pinion.
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post #15 of 28 (permalink) Old 09-21-2009, 07:58 PM
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Quote:
Originally Posted by Luke "Dobber" Veillo View Post
The bevel gear are the only gears that can be retreived without pulling the engine. The trans gears requires pulling the engine. To remove the the bevel gears, remove bottom side plate, and drive shaft on the front and the rear. The rear has a snap ring that has to be removed. Push the shafts together, and they can both be moved. Engine oil must be drained, then remove the four bolts on the back of the engine that hold the shaft that goes though the engine. Pull it out from the rear. The bevel gear will be on the shaft, and the pinion will be right inside of the engine. The pinion can be inspected without removal. If bad then the pinion can be removed by taking off the cover where the dip stick is. Remove the drive gear (I beleive a snap ring holds it in place) Then remove the four bolts that hold the pinion. I have a repair manuel from Kawasaki that tells how to remove the bearing from the gears. The bevel gear requires a special Socket. I made one with a peice of pipe and a welding machine. O and by the way, I your looking to increase top end, use Brute Force bevel gear and pinion.
Good info, thanks and good luck..you'll need some for the fix

08 LE,Ceramic coated Muzzy's,840 FST kit W/Port work,YFZ catch can,EPI clutch mod, OD Cap,hw jet kit,UNI Filter,TPI's,std Dyna cdi,SS112's,BigHorn 2.0's. If it's stock it sucks
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post #16 of 28 (permalink) Old 09-21-2009, 08:05 PM
 
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Quote:
Originally Posted by Luke "Dobber" Veillo View Post
The bevel gear are the only gears that can be retreived without pulling the engine. The trans gears requires pulling the engine. To remove the the bevel gears, remove bottom side plate, and drive shaft on the front and the rear. The rear has a snap ring that has to be removed. Push the shafts together, and they can both be moved. Engine oil must be drained, then remove the four bolts on the back of the engine that hold the shaft that goes though the engine. Pull it out from the rear. The bevel gear will be on the shaft, and the pinion will be right inside of the engine. The pinion can be inspected without removal. If bad then the pinion can be removed by taking off the cover where the dip stick is. Remove the drive gear (I beleive a snap ring holds it in place) Then remove the four bolts that hold the pinion. I have a repair manuel from Kawasaki that tells how to remove the bearing from the gears. The bevel gear requires a special Socket. I made one with a peice of pipe and a welding machine. O and by the way, I your looking to increase top end, use Brute Force bevel gear and pinion.
Great write up!
That info will definitely help some of the people that are unable to take their Teryx in to a shop for inspection and/or repairs.
The info provided above is correct, nice work!


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post #17 of 28 (permalink) Old 09-21-2009, 08:54 PM
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i had the same thing happen to mine it was the shifter cable easy fix
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post #18 of 28 (permalink) Old 09-22-2009, 06:22 PM
 
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I am new to the Terex. I have an 08 with 66hrs on it. Purchased used. was out this weekend using it on steep and rocky terrain. When decending hill in low gear it sounds as if there is a slapping noise like a chain. Any ideas on what it may be. Also at times when comming to a stop there seems to be a high pitched whine. Different than the fuel pump. Thanks for the tip on the strating in gear with the break on. I did it once and did not make the connection and then I had to fight getting it out of gear as is discussed on some of the other posting. Thanks Pat. 505-228-7106 or email hdhauser@comcast.net.

Is there a web site to download the shop repair book? Thanks Pat

Last edited by Pat Hauser; 09-22-2009 at 06:24 PM. Reason: Automerged Doublepost
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post #19 of 28 (permalink) Old 09-22-2009, 07:11 PM
 
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My teryx is currently in the shop getting fixed, the problem was a rounded off engagement pawl for the low gear. The symptoms were the transimision would make a very loud bang (metal on metal) in low gear and low gear only, and would occur around 15 miles and hour or anytime under heavy throttle greater then 75%. The shop first fixed a CV joint thinking that was the cause ($800) i wish that would have fixed it. The transmission job cost $2300 including parts. I hope thats not your issue. makes for an expensive toy.

-Matti
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post #20 of 28 (permalink) Old 09-22-2009, 07:46 PM
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Quote:
Originally Posted by drofmij View Post
step on the brake it will start in gear.
Thanks I will try that if there is a next time...
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post #21 of 28 (permalink) Old 09-28-2009, 04:21 PM
 
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Trans. Noise

Does any one have a popping noise sometimes when they get down on the gas from "0 to wide-open" in high or low range ?
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post #22 of 28 (permalink) Old 09-28-2009, 10:32 PM
 
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Trasmission noise

The noise I have experienced with my 08 is a sound like a chain popping when in low gear decending a steep grade. I have not tried the hard acceleration in low gear to see what happens. I talked to the service folks here at the Kawasaki dealer and they said it may be the spring on the front over ride system for drive line wrap up. I need to take it out and see what happens. Maybe later this week. Not a good noise that is happening on my Teryx., Let me know. Pat
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post #23 of 28 (permalink) Old 10-05-2009, 05:57 PM
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Transmission

I have mine loaded up to take it in the morning. The problem I have is when I an accelerating I hear a clanking noise that gets louder and faster the faster I go. When I take my foot off of the gas it quiets. It does it in 2wd and 4wd. never pops out of gear. I do have to rock it to get it into neutral sometimes. But it does it on flat land no matter what speed. The noise is getting louder and it bugs the crap out of me thinking it is going to come apart any minute.
So what do you guys think? Same problem?
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post #24 of 28 (permalink) Old 10-09-2009, 02:12 PM
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Talking update

My transmission had 2 teeth broke on the middle gear, the dealer broke an axle while putting it on the lift, and the front prop shaft joint is worn out. The extended warranty is going to cover it all. If you live in the Houston area Pasadena Kawasaki is the only place for service.
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post #25 of 28 (permalink) Old 10-09-2009, 09:22 PM
 
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Quote:
Originally Posted by Pat Hauser View Post
I am new to the Terex. I have an 08 with 66hrs on it. Purchased used. was out this weekend using it on steep and rocky terrain. When decending hill in low gear it sounds as if there is a slapping noise like a chain. Any ideas on what it may be. Also at times when comming to a stop there seems to be a high pitched whine. Different than the fuel pump. Thanks for the tip on the strating in gear with the break on. I did it once and did not make the connection and then I had to fight getting it out of gear as is discussed on some of the other posting. Thanks Pat. 505-228-7106 or email hdhauser@comcast.net.

Is there a web site to download the shop repair book? Thanks Pat
Slapping noise when descending a hill or getting off the gas, for that matter, is normal. Annoying yes. But normal. It has been discussed on numerous threads. The high pitch whine when coming to a stop is probably just a tight belt. Nothing wrong also. It will probably go away as the belt stretches a bit. The previous owner may have just adjusted the belt before selling it to you.
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