Kawasaki Teryx Forum banner
Cancel

Bevel Gear Nightmare

1544 Views 7 Replies 3 Participants Last post by  MisterKidd, 
MisterKidd
4
I bought my 2016 Teryx4 used. I love the vehicle. My last side-by-side was a 2007 rhino, so this feels like an upgrade. Anyway, I bought it with the bevel gear whine on deceleration. I had read up on the Teryx's and everybody was saying that they were noisy. So, I wasn't thinking that it was a problem. As time went on and I became more familiar with the machine, I started to think it wasn't normal. Read even deeper and started seeing people were having problems with the bevel gears. Opened mine up and sure enough, the bevel gear was loose.

I have all the new parts, but my problem is that Kawasaki replaced the 92210-0762 nut with part number 92210-1915. The special tool that I used to remove the original nut won't work on the new nut which has a much bigger outer diameter. Looks like I'm going to have to get a tool made as I don't see a new socket tool available for this replacement part. Just a heads up for anybody else tackling this fix. I included pictures of the original and replacement nuts and pictures of my poor Teryx. Hopefully it will be up and running soon.
Font Material property Gas Circle Automotive tire

Wheel Tire Car Land vehicle Vehicle

Tire Wheel Plant Vehicle Automotive tire

Tire Plant Wheel Automotive tire Motor vehicle
See less See more
Reply
Save
Like
  • Like
Reactions: 1
1 - 8 of 8 Posts
LiftedT4Le
Almost looks like a spanner nut on a dana 44 . wonder if one of those sockets might fit it??
Hope you got the Beast up & running & you can start the New Year right!!! I hope the redesigned nut solved or solves the problem you were having.
Reply
Save
Like
MisterKidd
Thanks for the suggestion. I actually did check out 4 pin sockets for the dana 44 and others. They were too big. However, I was able to use the special socket that I had purchased for the output bevel gear nut. Even though it was too big for the new nut, with some 3/16 x 1/4 square stock locked into the notches on the nut, I was able to tighten it to the 199 ft/lbs. See example below with the 3d printed mockup of the locknut.
Kitchen utensil Automotive tire Dishware Car subwoofer Serveware
See less See more
Reply
Save
Like
  • Like
Reactions: 2
LiftedT4Le
Welcome, Nice I'm sure that gave you piece of mind. 👍
Reply
Save
Like
C
Not to distract from your post but where did your roll cage come from? And can you send some more pics of it?
Reply
Save
Like
MisterKidd
3
CD3 said:
Not to distract from your post but where did your roll cage come from? And can you send some more pics of it?
Click to expand...
The company that made the roll cage is called Long Travel Industries.

Attachments

See less See more
Reply
Save
Like
MisterKidd
So, just about 5 months later i got the motor all together and put back in the Teryx. Never timed a V-twin before. Kind of a pain. Wish I had taken better photos of all the electrical connections since some stuff is aftermarket. Anyway, had a hard time getting it started. I had forgotten to pull the rubber gloves out of the throttle body intakes. Got it started and took it for a quick drive. No more gear whine. I will get some video and post once I get the plastics back together.
Reply
Save
Like
MisterKidd
Here's the link to the promised video...still getting used to the drone.

https://youtu.be/ZdExVrCUfXM
Reply
Save
Like
  • Like
Reactions: 2
1 - 8 of 8 Posts
Kawasaki Teryx Forum
A forum community dedicated to Kawasaki Teryx owners and enthusiasts. Come join the discussion about performance, trails, modifications, classifieds, troubleshooting, maintenance, and more!
Full Forum Listing
Explore Our Forums
General Teryx Discussion Teryx4 Engine and Drivetrain Teryx's and Parts Wheels and Tires
Top