Project Kawasaurus - Retro ATV Build! Front Diff Rebuild - Kawasaki Prairie/Brute Force 650 : EP 02

[@utahwanderlust700]

Polaris front diffs are not real locking front diffs. They are essentially Hilliard clutch packs and not manually controlled like the Kawasaki. Kawies may be complicated, but they work great, and are a real locking differential. I wouldn't have anything made by Polaris even if you gave it to me for free!

[@TheWasillamike]

Polaris front diffs. are prone to blowing apart more so then these Kawasaki diffs. Over built, but reliable!!

[@beerbikesburnouts3300]

In the video i could be wrong but it looks like you put the center in upside down ?

[@Itsa_Mea]

Just doing one of these yesterday, I agree. The clutch pack/basket is upside down.

[@shaunlucky-samaroo688]

Have any updated videos of the atv

[@marcelosalvo3131]

Good videos keep making more

[@adrew1963]

do you have to pull the handle bars off to pull the front diff?

[@AdrenalineJunkieProd]

No you don’t.

[@adrew1963]

but you have to pull out the steering stem as far out as can go right@@AdrenalineJunkieProd

[@AdrenalineJunkieProd]

@@adrew1963 ya, but you can do it with the bars on. You may need to remove your brake levers and throttle. So that way have room to move it up.

[@adrew1963]

thanks @@AdrenalineJunkieProd

[@algomaadventures6992]

When will we see more build vids?

[@honkytonkman123]

U have a part number for that expensive seal, cant find a listing anywhere.

[@AdrenalineJunkieProd]

I'll try and dig up the part number. Might still have the package it came in.

[@JamesMorel-yw2fd]

Honestly how hard would it be to 3d scan this diff and get the outside dimensions to match and just change the internals to a simple ring and pinion with interchanging gear sets then just find cv axle that bolts on the outside so the insides sealed

[@AdrenalineJunkieProd]

Doubt it’s worth the effort on such an old and obsolete machine. The diffs work, they are just over complicated. Compared to a Hilliard style diff that’s used in Polaris this one has so many unnecessary complexities.

[@frankmaio7106]

I'm doing the same thing. Do you have any pics or anywhere I can find how the spacers and shims go?

[@adrew1963]

were you able to find any good infof I am going to pull my front diff soon its beat maybe I should buy a used one but so expensive

[@alsmith5970]

Do not put the diff together this way. the clutch pack is upside down

[@AdrenalineJunkieProd]

huh? What's upside down? It works perfectly.

[@Michaeljallen1978]

​@AdrenalineJunkieProd When you put the clutch pack in on the video it was upside down. The large teeth are supposed to face outwards towards the axel that's how it grabs the axel to lock in.

[@honkytonkman123]

How did you get that pinion bearing on, no one ever addresses that part.did you actually rebuild or just bought the differential complete

[@AdrenalineJunkieProd]

Like I mentioned at the beginning I replaced the seals and bearings that needed to be replaced. The pinion bearing seemed fine so I didn't see a reason to replace it. I left the original in place.

[@honkytonkman123]

@@AdrenalineJunkieProd you have any info on the pinion bearing,does the cog separate from the nut

[@aeror115]

Cool project buddy! It’s getting colder over here so the workshop project time starts soon 👍

[@AdrenalineJunkieProd]

Thanks. Ya, exactly. I wanna get this thing done in the next couple of months. It’s been sitting In pieces way too long.

[@СергейКостюков-б8х]

@@AdrenalineJunkieProd хх

[@СергейКостюков-б8х]

@@AdrenalineJunkieProd ххх

[@tonyfrank8528]

Who designed that, Mercedes Benz? Lol stupid design. Polaris diffs are way better

[@AdrenalineJunkieProd]

LOL, hahaha. Ya, the Polaris diff is so damn simple in comparison. I'm not sure what the new Kawasaki diffs look like inside. Keep in mind this one is 20 years old.

[@JamesMorel-yw2fd]

Quit crying or build one better wahhhhy 😢