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I was faced with an expensive engine repair on my 2008 Teryx, and I discovered that I could buy a complete engine assembly from Kawasaki that would save me money instead of rebuilding the old one, but the only engines they had were for the 2013 model – quite different from the ’08 or so I thought. I did a little checking around and it looked like it would be a feasible conversion, so I took the gamble and bought one. The following is what you can do to an F.I. engine to make it work on a carburetor engine:

1. Remove the old engine from the Teryx and place alongside the new engine (it was easy to compare and swap parts that way)

2. Remove the water pump covers, impellers and generator covers from both engines.

3. You will need the Kawasaki puller to remove both flywheels (watch out for the flywheel woodruff key, it could fall out of the crank and into the engine)

4. Notice the difference between the flywheels, you will need to install the ’08 flywheel on the ’13 engine. But before you do, you’ll see they beefed up the starter gear on the ’13 engine, so swap out the gears as seen in the pictures:



5. Degrease the flywheel taper and the crankshaft taper and install the ’08 flywheel on the ’13 engine making sure you also install the starter clutch idler gear at the same time. Use the flywheel retaining bolt from the ’13 engine and tighten it to 94ft/lb

6. The stator for the generator looked different, so I swapped it and the pickup coil as a set.



7. Use new gaskets and install the generator cover, water pump impeller and cover. Use silicone sealant around the grommets where the wires emerge from the cover.

8. You will see that the mounting lug where the thermostat housing bracket goes has a new size hole – 8mm from 6mm, so drill the bracket hole to 8.5mm to allow some adjustment and find an equivalent length 8mm allen bolt to hold the bracket. Now swap both the water pipes. I used the new o-rings on the water pipes that I removed from the ’13 engine. Grease them before installing:



9. Remove the airbox mounting bracket and rear cylinder intake valve cover from the ’08 engine and install all those parts including the bolts and o-ring on the ’13 engine. The valve covers on the new engine are taller and would cause an airbox misalignment. You only need to change the one valve cover:



10. Swap the starter motor wire, the new one is too short:



11. Swap the rubber intake manifolds and the crankcase breather tubes:



12. That’s all you need to do to the engine before installing it to the vehicle. Just one area of caution and that is the cooling hose at the front of the engine from the thermostat is quite close to a new lug on the cylinder head. Run a file over the sharp edge and make sure there is clearance for the hose:

 

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Big Willie
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about how much time did this project take and of course cost billybob11?
 

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Nice write up!
 

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Nice write up! :icon_thumleft:

(Honestly, I was typing that at the same time Ali baba was!)
 

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El Moderator
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:icon_thumleft:

Awesome!!! Pretty sure the '13 has a slightly higher voltage output on the stator (reason for the difference).
 

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Excellent info.
 

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Did you turn the engine over with hand tools to be sure there was enough clearance on the valve train with the shorter cap. Or did you already know it would clear. And good info!
 

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I hate to put the fly in the ointment. Anyone considering this the 2013 still has the same bad valves as Kawi has been using, so you may and I say may have to go back yet again to replace the valves. If I had to buy a new engine not get mine rebuilt I would remove heads and swap valves and springs and put new head gaskets on then it would be good for a long time.

Todd
 

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Todd, I'm still on my stock valves with over 4,200 miles of hard dune riding and only one valve adjustment just because. Am I lucky or what?
 

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Lucky I guess, maybe I just see all the bad ones.

Todd
People very rarely stop by their mechanics to tell them their car is running fine... ;)
 
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People very rarely stop by their mechanics to tell them their car is running fine... ;)
I thought the same thing when I read it. I can imagine that conversation.

Hey Mr Mechanic just wanted to stop by and tell you how good my stock valves are doing. Do you mind tearing my engine apart so you can look at them......Oh and I'll pay you for that.:razz:
 

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A fresh motor in my 08 would rock! I see these 2013 crate motors still on sale. One place came up under a "Teryx crate engine" search for 3k price and free shipping. There's always Muzzys for around 3500. Did anyone understand the swapping of the flywheel? Billybob was pretty quiet when people asked questions.Was it a clearance or voltage issue requiring the flywheel swap, you think? EDIT.....I just checked the wiring from my 08 coil and stator..The 2013 motor seems to use different leads from the generator, I'm guessing the new flywheell and stator may work but for a plug and play install the flywheel swap was just to guarantee everything worked like OEM. I'd really like to hear how this ran, its a killer write up. Looks better than some shop manuals I've seen.
 

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2013 engine to fit 2008 teryx

Hi. Great post you did with detailed pictures. I may have to go the same route or spend a bunch of dollars for engine rebuild. How s your teryx working now? Any problems down the road with new engine in 2008?
Did you need to do this because if dirt in engine? Love to get a response. Hubby and I live in so cal and I think you do too. Anaheim
We ride mostly in Blythe and arizona
 

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Discussion Starter #20
Sorry for the late post. I must have missed this one. Teryx is running great, no issues now. The 2008 was bought used and it wasn't treated very well by the prior owner. The swap was pretty straightforward besides the transfer of parts from the old engine.

I live in socal, Garden Grove. I usually hit up Johnson Valley for most of my riding but like to do Glamis, Ocotillo, Pismo, Calico when I can.

Hi. Great post you did with detailed pictures. I may have to go the same route or spend a bunch of dollars for engine rebuild. How s your teryx working now? Any problems down the road with new engine in 2008?
Did you need to do this because if dirt in engine? Love to get a response. Hubby and I live in so cal and I think you do too. Anaheim
We ride mostly in Blythe and arizona
 
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