Kawasaki Brute Force motor disassembly

[@TOWLIFE1731]

Thank you so mutch, you learned my how to open up these big engines. Without you this would not have been possible

[@carlinwhite6915]

This video really helped me take my case apart. Thanks for taking the time to make it!

[@FourwheelerDoctor]

Thanks for watching

[@digger_jon2778]

Thank you for taking thw time to help us 750 owners I appreciate you fir it

[@scottsheffield2594]

I followed your video to teardown my Brute 650. I just finished. Thanks for your detail and saying what size sockets are needed. Mine is like this one the front rod bearing is bad. I'm taking the crank tomorrow to have it reworked. I will be following your reassembly video too once I get all the parts.

[@FourwheelerDoctor]

Glad I could help!!

[@vadimichs4211]

Just took it apart. So far so good. Thanks for such detailed video

[@robertmcilhennyii9841]

Thanks for making this . Huge help ! for a spun bearing on crank can i get away with reusing rod ? Thanks again.

[@FourwheelerDoctor]

Most of the time you can reuse the rod. I usually let my engine guy clean it up with his hone.

[@scottsheffield2594]

This is a great video, lots of detail and I really like that you explain everything very well. I just bought an 06 Brute 650 not running. Guy showed me a video of it running it smokes and a knocking noise. I have low compression on front head 28 psi and 90 psi on rear. I think it was sunk in water just guessing. I know it needs rings and once I pull heads I will check the crank bearings like you showed and see what else it needs. Your video was great at showing how to tear it all down. First question is what symptom would a spun crank bearing be? Second question when I picked this atv up it rolled easy put it on trailer set parking brake and the guy put it in gear and I strapped it down. Strap came loose and the atv moved on trailer a little. Now I put it in neutral and release park brake and can hardly move it. I jacked up rear end and its real hard to turn rear wheels. Have you seen this before and could it be the rear wet brake stuck or something in transmission? I know when I remove the engine I can try and turn the rear wheels and I will know then if it is problem in rearend or transmission at that time.

[@FourwheelerDoctor]

The spun bearings often times show different symptoms. I will just list all the the ones I can think of. Bottom end knock, loss of power, starter dragging/ hard to turn over. I would about bet your front rod bearing is spun. As far as your brakes go. I would guess your cable was sized for the rear brake. See if you can get the arm where the cables attach to the front of the diff to move. It should release the brake. I doubt it has transmission trouble.

[@scottsheffield2594]

@@FourwheelerDoctor Thank you for the information. Thanks for the tip on getting the brakes released. I'm eager to tear into the motor after watching your video. I will be subscribing.

[@scottsheffield2594]

@@FourwheelerDoctor I finally got the motor pulled and pulled the heads. You were right on it with what you thought was wrong with mine. I found the front rod bearing is bad that thing moves all over the place. Also the cable for hand brake rear was froze up. I'm going to be following the rest of your video to open the case later this week. Thanks again for your great videos.

[@Atomotechnologies]

Where do rou rebuild your crankshafts? I have exactly the same problem

[@FourwheelerDoctor]

I have a local guy that does them for me. There are a few folks on Ebay that are fixing them much cheaper than going back with an oem new on.

[@frankmaio7106]

What is the cause of the spun bearing and how hard is it to get the engine out of the quad? And awesome video, thank you

[@marcosmorelos6324]

whats the part inside 34:16 that gets between the shifter because i removed that part after i pulled out any advice you gave me will be great

[@grandcrappy]

Very informative vid thanks, give us more.

[@craigbehnke5460]

Was just wondering when you might be doin a reassembly video? By the way great breakdown on disassembly really great instruction.

[@FourwheelerDoctor]

It has taken me a little bit on this one but I have all of the new parts in the shop now. I should have a video in the next week or so

[@craigbehnke5460]

Four wheeler Doctor that’s awesome I bought 2 of these for $1300 and I think one has a blown head gasket the other runs but this video would help a lot in case the one has to be tore down further or if it needs new chains

[@FourwheelerDoctor]

I finally got the reassembly video uploaded. kzbin.info/www/bejne/jZyWg5dvqJeNgM0

[@boyzwillbeboyz2648]

Any idea what would cause antifreeze to just pour out the oil drain after all seals have been replaced? Great video btw. So much detail

[@FourwheelerDoctor]

Sounds like a bad seal in the water pump or a cracked head.

[@boyzwillbeboyz2648]

@@FourwheelerDoctor thank you. I will do a leak down test if all goes fine will buy another seal kit. Thank you again.

[@keithbennett1359]

Excellent video , I have a customer's 2014 Brute force 650 (this model seems to be Canada only, no 2014 's any where else ) with spun rod bearings , the engine is in good shape otherwise , the 17yr old owner really abused this thing and is likely the cause but I need to be sure it is not the bushing/oil pressure. the manual gives ranges for the bushing and journal but no acceptable tolerance . I measured them and the clearance is about .0035 . the manual says journal service limit is 1.652 and the bushing service limit is1.6567 so I assume the clearance here would be .0047 if I am reading this right ???? your thoughts would be appreciated. Keith's Mechanical

[@CriticalWeldingCompany]

If I have a knock in the transmission and I split the case just for transmission repair should I have to adjust the valves due to new seals or will it be fine. And when I do reassemble is there a special procedure to get it back to running like lining it in top dead center on the front piston or does any of that matter. Trying to do it myself and learn along the way

[@FourwheelerDoctor]

You may have to adjust the valves. I have a reassembly video I will have uploaded this weekend that tells the top dead center steps. There is a pattern you have to follow.

[@CriticalWeldingCompany]

I have a 2014 brute force 750 gotta get a clutch and flywheel puller then i get things on the ball. But until then I'm just making sure I don't dive in to deep and get lost.

[@FourwheelerDoctor]

@@CriticalWeldingCompany my next video should show you everything you need to get it back together

[@CriticalWeldingCompany]

Thank you very much sir!

[@FourwheelerDoctor]

I posted the reassembly video yesterday. Check it out.

[@hertzrivero6561]

Saludos tienes respuestos para kawaskai brute force 750?

[@DeathLivezs]

Thanks man your a champion

[@FourwheelerDoctor]

Thanks for watching

[@ekalb7789]

Thank you

[@FourwheelerDoctor]

Thanks for watching

[@brandon6451]

I swamp my bike. I'm looking into splitting the cases to clean it all out. Im guessing flushing it won't be as good. How deep do I gotta tear things down to clean it out so sand don't tear things up?

[@tdubfpv3380]

My brute just made a horrible noise all of a sudden at idle and engine seized....im gonna attempt a rebuild. Cheaper to get crank machines or get new?

[@yonallopez]

Why my 04 kawa prairie the reverse works but does not seem to completely engage forward ?

[@michaelshearer2513]

You mentioned the Phillips bolts getting the heads pulled through the plates holding the crank bearing. I pressed mine out and it pulled the them through.. threads are good in the case just messed up the head when they pulled through what did you do to fix ... if you simply replaced bolts where did you find them?

[@FourwheelerDoctor]

Part number 221AA0616. Motosport.com has them in stock for less than $2 each.

[@jesusfirstc]

Awesome videos life saver 😊

[@hdmbrute]

Great video man. Can I remove my tensioners on the outside of the engine (rear tensioner) and reinstall them without it jumping time? I’m hearing a light chain slide coming from right where the tensioner is.

[@FourwheelerDoctor]

Yes you can just make make sure you have the cylinder at TDC before removing the tensioner

[@ciaranhutton1467]

Hi can you tell me how many hours you had on the clock when you had your crankshaft reworked

[@user-ym9wb2mk5e]

Thanks for the video! About to pick one up in a few hours, already know engine is “bad”, but no actual specifics so not sure what I am about to get into, lol. This video helps a lot. Sounds like spun bearings are typical for this specific engine design if people are wheeling a lot?

[@FourwheelerDoctor]

Yes they are. That is the most common problem I see with these.

[@perro903able]

How much difference is it between a 08 fuel injected to this motor?

[@FourwheelerDoctor]

The motor is exactly the same. Only difference is the fuel delivery system and the amount of pickup points on the flywheel.

[@broganjk1988]

So I may have a dead stick on my hands. 2 valves on the front head of a Bruteforce 750 are full of water and rusted. Is there any hope. HELP!

[@FourwheelerDoctor]

Intake or exhaust and where did the water come from. Was it left unassembled or is coolant?

[@WeRideWV]

Please help. Can i drill a rear cylinder head(has bosses for it) for a chain tensioner and use it as a front cylinder head? I have a 2005 BF 750 4X4I

[@FourwheelerDoctor]

Yes it can be done

[@WeRideWV]

Thank you. I have an extra one but wanted to make sure before I drilled. Thanks again

[@rickystone4137]

I need some help with a Kawasaki Prairie 400 4x4..I have no reverse..it will go in gear but not move, like its in neutral..forward works fine

[@marshallives658]

Hey man my 07 prairie 700 which is basically the same motor blew the front head gasket and while I have the motor pulled I’d figured I’d replace all the chains because they where bound to go out anyway. Do I need new headbolts when I reinstall the heads?

[@FourwheelerDoctor]

I have never installed new head bolts as long as they aren't damaged.

[@marshallives658]

@@FourwheelerDoctor Ok thanks, a buddy of mine said they looked like stretch bolts and i should replace them

[@dustintownsend7810]

Where do you live ? I'm from Maryland You could get big doing this ... your very good at it there's nobody around where I live that dose work like that maybe the dealership

[@FourwheelerDoctor]

I'm from South Carolina and I already have more work than I have time to do. Lol

[@dustintownsend7810]

Thats good man nothing wrong with that at all wish you luck you definitely know how they work ill be watching 👀 👍

[@barryhyrne1539]

Who does machine crank work ? Where r u located for engine rebuilding? Barry hyrne

[@joecrispell6609]

Where did you get the flywheel puller???

[@landonnagin4273]

NICE!

[@FourwheelerDoctor]

Thanks for watching

[@robbie449]

Anyone know what the bearing is called he is talking about at 10:00? Looking to order one but can’t seem to find it in the parts diagrams.

[@FourwheelerDoctor]

BEARING-BALL 92045-1403

[@robbie449]

@@FourwheelerDoctor thank you!

[@Dfarnham100]

I have a question I’m down to the crank and in you video you mentioned sending it out what do you mean by that? Thanks

[@FourwheelerDoctor]

Instead of buying a new crank I have my cranks machined where they cut down the rod journal and use aftermarket oversized bearings to get the play out of the rod. I have a guy at a machine shop that does it for me.

[@Dfarnham100]

@@FourwheelerDoctor thanks for getting back to me,.. I do not mean to ask stupid questions,.. so basically you have two options then,,.new crank or get it done, you can’t just put new rods and bearings? On the crank? Cheers

[@FourwheelerDoctor]

@@Dfarnham100yes those are your two options. normally the crank is damaged by the bearing spinning and you either have to have it machined or replaced. Take your rod off your crankshaft and inspect the crank journal. It probably has deep scratches in it that will not allow a new rod bearing to rotate properly

[@Dfarnham100]

@@FourwheelerDoctor I just went and pulled the connecting rods and the crankshaft looks good, no scratches or scaring do you happen to know what the tolerance should be? As you know cranks are expensive what does the shop normally charge to get it work if you don’t mind me asking? Thanks a lot for answer my questions,.. I really appreciate it!

[@relaxingnature2617]

2008750brute..Ive got no spark and have tryed everything ..Apparently I need to change my crank position sensor ..is a crank position sensor the same as a speed sensor ? at 33.00 sec I see only 1 sensor .. yours looks same as mine ..my repair diagram shows 2 sensors ..your video shows the outside sensor ..its is called "speed sensor reverse" ..and the inside one in diagram is called "speed sensor" ..my 750 looks identical to your video ..is there a second speed sensor hideing inside somewhere ? ..note my diagram has 2 separate part numbers and the outer "speed sensor reverse" has a square metal tip ..that is the type I pulled out of my quad ..the one with no metal tip is hideing I think .. ??? ..does speed sensors also do crank position duty ? ..or is a speed sensor just about the speedometer ? ....next question,next to the stater is a pickup coil ..it it possable that pickup coil does crank position sensor duty ?

[@FourwheelerDoctor]

The pickup beside the stator is the sensor that controls when it fires. I didn't get a picture of it in my video but it is just out of the top of the frame at 9:43. The speed sensor only controls the speedometer and can cause some errors with the front diff shifting into 4wd. The sensor you are chasing is behind the left engine cover at the stator.

[@relaxingnature2617]

@@FourwheelerDoctor ok ..thank you very much ..i did a ohms test on my pickup/cps i got a reading of 414ohms ..the spec says 423-517 ..i also have a spare pickup/cps from a quad that fell off a truck and rolled .. it measures 418ohms ..its sensor is out of spec but that bike ran ..hmmm

[@edyanac9957]

Hello, Looking for someone to rework the crank on a 650, can you help me out? Also what is the cost difference on a rework vs new? Thanks

[@ralphlawson8294]

Were did you get your clutch puller

[@FourwheelerDoctor]

I bought it off ebay. I'll go ahead and tell you don't skimp and get the cheap one. You'll thank me later

[@raindropdroptop3286]

I have an 08 650 that has low compression after getting water in the air intake do you have any idea what are some possible problem parts? Also where did you source your parts? First time doing anything this deep so any information would be helpful!

[@FourwheelerDoctor]

Sometimes it can make a ring stick on the piston.Try and put some oil in the spark plug hole and see if will make the compression get up enough to allow it to crank.

[@iragecamp9382]

hey just a question so i just bought a bruteforce and behind the dip stick oil cover their is whole in the side of the case do you know what can cause that to happen. just wondering

[@FourwheelerDoctor]

There is a gear behind the dipstick cover that drives the output shaft. There is a chance a piece of metal from something else broken inside the engine getting under that gear and popping a hole in the case. It's not hard to pull off the dipstick cover to inspect.

[@iragecamp9382]

@@FourwheelerDoctor ok thanks i was just wanting some input. im about too. i went ahead and ordered a new crankcase since their is a whole on the side of it. thanks again!

[@garyrobinson219]

What brand clutch puller are you using? Just broke one luckily I was able to get it out fairly easy. Not wanting to try my luck again though lol.

[@FourwheelerDoctor]

The one I use is an epi. I found out the hard way too that I needed to buy a good one.

[@christopherbowling4249]

Do you know how to get all the bearings out of the case?

[@FourwheelerDoctor]

I very seldom replace them but the best way to get the ones out that you can't get to the back side is with a blind bearing puller. I have this one www.harborfreight.com/slide-hammer-and-bearing-puller-set-5-pc-62601.html Some auto parts stores will let you rent them as well.

[@christopherbowling4249]

Thanks, after replacing the main bearing and bushing, should you line bore the case?

[@FourwheelerDoctor]

@@christopherbowling4249 I have done about 10 of them and have never line bored the case. If you don't mind me asking, where did you get your left crankshaft bushing from?

[@e-man8469]

What are the typical reasons for water in oil on this particular engine?

[@FourwheelerDoctor]

Has it been run under the water that you know of?

[@e-man8469]

@@FourwheelerDoctor Don't know. It runs good, but gets water in the oil. Change the oil, happens again.

[@FourwheelerDoctor]

There are really only three places to get water in the oil on these bikes. it could be your mechanical seal and oil seal on the water pump shaft. Both of those would have to be bad for water to get in the oil. Not real likely that's the problem. The other two places to get it in there is either the head gasket. Or your head could have a crack in it. I've never had a problem with head gaskets leaking on these but I have replaced a few cracked heads from time to time

[@e-man8469]

@@FourwheelerDoctor This is great advice. I appreciate your help!

[@e-man8469]

I've got new heads and valve covers installed, they were cracked, i'm thinking I may be 180 out, i get compression coming out the carbs. does that make sense?

[@cohenarcemont3078]

How much do you normally charge for something like this? Currently in the same boat

[@scottsheffield2594]

What size flywheel puller did you use? I need to order one.

[@FourwheelerDoctor]

I am pretty sure the one I have is 35mm.

[@dustintownsend7810]

I learned alot man Your the man lol ,...... did it run at all i have a 08 about to get redone

[@FourwheelerDoctor]

Yes it would run just had a bad knock.

[@randykynard5657]

I had mine rebuilt 60 hours later it lost compression 15 psi each cylinder

[@The_Home_Pros]

Man I love ur videos you are awesome at what you do but I cringe so bad watching u take the engine apart when it’s so dirty, and watching all that dirt fall in the engine and on the parts, a quick pressure wash wouldn’t hurt

[@digger_jon2778]

It's a waste of time when everything is coming apart and getting replaced anyways.

[@markconley9279]

Should’ve washed the engine first.