Explicatives belong here. Since new my 08 teryx has had terrible gear noise that has progressively gotten worse. It has gotten so loud that I feared it was going to leave me stranded. After reading some other posts I checked the bevel gears and they are toast. There are chunks out of the bevel drive gear. The teeth that are remaining have a terrible contact pattern. While under warranty my rear seal was replaced 3 times. I would have thought they would have noticed the bad contact, but that is a bad presumption. This will be the last Kawi product I will buy, and I was considering a teryx 4.
Now I have to fix this and try to get the gear material out. Anyone know of better gears? I have essentially babied this thing and it has 1k miles on it, All trail, no Mud, and I have 26” tires on it. I cange the oil every time I ride. Its clear this is a factory defect

Sorry to hear about your bad luck. The stock gears are fine, normally. Maybe the dealer changed something when they did the seals?

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Chris@BenchmarkPerformance.us
Benchmark Performance
760-484-0986
Engine Specialists, Side x Side Parts & Accessories, Discount OEM Parts

No problems on my 08...and I beat the piss out of it...keeps coming back asking for more...

You sure your linkage is in specs for adjustment?...

The gears are usually just fine and pretty damn robust! I would say it is bad luck. Replace with factory gears and don't look back..

Ill post some pics tonight, its clear to see the contact pattern is on the edge of the gear. Its hard to believe they set it up that way.

I blew my bevel and ring gear both up. Like you I was having a loud noise, and one day it exploded on a ride. Took engine out, and installed a Big kev standard bore kit along with the gears.LOL.....good luck

That sucks...what kind of oil are you using in the rear diff?

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2008 with 240 hours,Fundy STD Bore Kit, Muzzy Duals ,Hunterworks Carb Kit ,Dynatek C.D.I. Uni Filter ,Dalton Clutch Kit +O.D. Cover ,Kolpin Dual Gun Holders ,Warn XT 3000 Wireless Winch ,TYRI L.E.D. Lights,Custom 500 Watt Stereo ,Custom Cut Lexan Windshields , Full Guages and 28 inch Maxxis Mudzillas

Soon to fab 4 seater with boat rack

I use lucas wet brake fluid in the rear diff. The bevel gears are submerged in the engine oil though. For engine oil I use castrol TWS at 15$ a quart, no longer will I do that, seems a waste.

I think muzzy sells a overdrive bevel gear....this whole time i thought you were talking about the rear diff...oops

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2008 with 240 hours,Fundy STD Bore Kit, Muzzy Duals ,Hunterworks Carb Kit ,Dynatek C.D.I. Uni Filter ,Dalton Clutch Kit +O.D. Cover ,Kolpin Dual Gun Holders ,Warn XT 3000 Wireless Winch ,TYRI L.E.D. Lights,Custom 500 Watt Stereo ,Custom Cut Lexan Windshields , Full Guages and 28 inch Maxxis Mudzillas

Soon to fab 4 seater with boat rack