Some of you might remember in 08' and 09' there seemed to be a over heating problem with 840 kits causing them to blow head gaskets.While I'm sure in some cases there were over heating problems in harsh conditions it always bugged me why some stockers were over heating.

I have been working on these motors for 9 years now and I have chase a few head gasket problems in my time of building big bores,and 90% of the time it has to do with either the head or the cylinder surface. If the two surfaces are not perfectly flat there is no way you are going to keep from blowing head gaskets.That brings me to what I have seen since the first Brute Force 750 came out in 05'.While it wasn't a big problem back then,the Teryx with more load to the motors and the fact that the motor is covered it became a issue.It seems that at the end of production some of the last heads to be milled were getting rough surfaces from dull cutters.

If you look at these pics you can see the lines from the cutter going from the combustion chamber over to the water jackets. Now on a stocker it may or may not have pushed compression into those grooves over to the water jackets,but I beleive some were causing people to "think" they were over heating the motor as the coolant was pushed in to the over flow tank.But then there were some that went to 840's and the problem didn't get fixed,in fact with the bore being closer and the compression higher they had more problems.

I remember some customers saying they over heated their stockers so if they were going to pull it a part they might as well go to the 840 kit. I would tell them if they did over heat them that they better have the heads "ground"flat to be safe. This brings me to the next thing,notice I said "ground" and not milled.The milling is what Kawasaki does and it can cause little grooves. When you get them ground it is perfectly smooth. Not all stock heads look like they have been milled when the cutters are new as you can see in the pic of the head that dropped a valve.

The pic of the cylinder is what they look like ground.

I'm just bringing this to your attention so if you have had head gasket problems you know what to look for and what to do so you don't chase a problem around like some do. I get customers buying 4 gaskets at a time and they just change head gaskets and they don't fix the real problem.

Now I have not been building as many motors in the past year with my broken arm so I have not see the problem on the newer 10's or 11's so I don't know if this is still a issue but I have let Kawasaki know about this in the past.

GOOD INFO

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One more pic of what a milled one looks like.

nice micky

Hey Mickey. Bit off topic here but I had your 840 kit. You may remember or not but we actually sent it to you for some work awhile back. Anyways There are some 840 guys on the forum here claiming 100rwhp. Is that possible without a turbo or nos or something? Mine was like mid 60's you thought with no head work. Just thought I'd ask. I have jumped ship and went with the xp rzr and just wondered if something had changed with the 840?

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08,fst 840,triple x seat package,pds k2 cage,k2 48" bed,fusion head unit with 8" rockford speakers, muzzy pro exhaust. DASA/FUEL LONG TRAVEL

think that was at the crank not the wheels.

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To that I might say maybe. The thread is active, one about sand tires and they are needing tires for 100 rear wheel hp! I want to call B.S. so bad, but they are headed to the dyno Monday so I should be able to hear the heartbreak all the way here in Missouri.

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08,fst 840,triple x seat package,pds k2 cage,k2 48" bed,fusion head unit with 8" rockford speakers, muzzy pro exhaust. DASA/FUEL LONG TRAVEL

That was on one of dynorays BS trips.

I think he has one of Dynoray's 880 kits and I think we are all curious to see what it puts down on the dyno.

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2009 Kawasaki Teryx Sport Long Travel Industries +5" suspension, FU2Chassis 4 seat cage, Induced Fab doors, (4) 26x9 DWT Moapas, DASA exhaust w/quiet cores, DASA impeller, DASA OD clutch plate, DASA KEBC block off plate, MSD, bored out throttle bodies, FuelUTV Siphon break, LTI UNI air filter, lime green secondary spring, TripleX rear bench, KBrown Customs oem replacement HIDs, 4" HIDs on the A pillar, Fiber Skinz diff skids, UTV Inc. Temp gauge kit, UTV Inc. fan bypass.
Safety is no accident

I think you are right about it being an 880 rather than an 840. Still no naturally aspirated motor in this displacement range will hit that number without something extreme I think??..

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08,fst 840,triple x seat package,pds k2 cage,k2 48" bed,fusion head unit with 8" rockford speakers, muzzy pro exhaust. DASA/FUEL LONG TRAVEL

don't think so i have seen injected 999cc bbk's around 130 rwhp

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I think you and I agree then??

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08,fst 840,triple x seat package,pds k2 cage,k2 48" bed,fusion head unit with 8" rockford speakers, muzzy pro exhaust. DASA/FUEL LONG TRAVEL

yep agreed didn't have my glasses on.

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Ray told him one hundred but thats crank but he probably think its at the wheels.

I think thats one of rays ways of misleading people into buying his kits. Then when they are pissed and call him a liar he says no I told you that was at the crank. One of rays ploys

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A 880 is just going gto get a few more Hp than a 840. Maybe 3.