Kawasaki Teryx Engine Rebuild - joshuarothfuss/projects GitHub Wiki

In 2021, a none-running, basket-case UTV was purchased. It had a 750cc carburated V-twin. The seller said that it burned oil before disassembly. The goal was to do an engine tear down, only as deep as necessary, fix it, and sell it. The piston rings has worn through the cylinder lining and oil was leaking through it.

Tools/Skills Used

Metric Wrenches (Box-End and Open-End)
Torque Wrench
Screw Drivers (Assortment)
C-Clip Pliers
Compression Meter
Rubber Mallet
Drill
Impact Driver
Kawasaki Clutch Wrench
Depth Gauge
Feeler Gauge
Valve Lash Wrench
Patience
Fine Tuning
Electrical Testing

Tear Down

The piston rings has worn through the cylinder lining and oil was leaking through it. To get to this point, everything around the engine had to be removed. Once it was just engine, the carb, the value covers, OHC, valve body, and then the cylinders were removed. Pistons, rings, and cylinders were then ordered. The urge to buy higher compression components was kept under control. The valve body was checked for any warping, and it was found to still be true.

Assembly

Once the parts arrived the meticulous process of the reassembly was started. Pistons, rings, gasket, cylinder, head gasket, valve body, cams, timing, valve covers, and then valve lash. On multiple occasions, I had some choice words for the engineers at Kawasaki. The hardest part was getting the timing right. The dual carbs were a little beyond my equipment, so I had a local power-sports shop tune it. Before selling I cleaned the plastics and put on new tires.

Result

In the end, it ran very well and looked better than it had in a very long time. In the end it was sold for 400% what I had into it.