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Old 07-16-2012, 09:35 AM   #1
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Lightbulb Common Mechanical Problems of Prairie 650/700 & BF650sra

Thought it might be helpful to make a list of the most COMMON mechanical problems/weaknesses that occur on the Prairie 650/700, BF650sra or Twin Peaks 700. This list could be helpful for new owners and/or someone interested in buying one.

I'll start the list (in no particular order)...please post below with any suggestions you have to add to this list.


PRAIRIE COMMON MECHANICAL PROBLEMS:

1) Stock oil seals on engine and front/rear diff tend to leak; Fix: Keep an eye on them and replace as needed (no aftermarket seals available at this time).

2) Stock front strut springs are too soft for fast-paced riding; Fix: replace with aftermarket strut springs.

3) Stock airbox snorkel is too restrictive; Fix: replace with Napa Hose Mod and/or 12 hole mod in airbox lid and increase main carb jets as needed.

4) Stock CDI is very restricted; Fix: replace with aftermarket CDI to eliminate low speed and top speed retarded ignition timing and to increase maximum ignition timing.

5) Stock swingarm bearings tend to wear out prematurely, especially if mud riding often; Fix: Periodically disassemble and apply grease and/or keep an eye on them and replace as necessary.

6) Stock radiator tends to plug up with dirt/mud and cause engine overheating; Fix: Thoroughly clean the radiator fins with a water hose on a frequent basis (don't use a pressure washer), especially needed after a muddy or dusty ride.

7) Stock '02 Prairie 650 carbs had weak choke springs that sometimes caused gasoline to fill the engine while not in use/Newer model Prairies sometimes have sticky choke plungers that cause poor idling/running; Fix: Replace the '02 Prairie choke springs with '03 or later Prairie choke springs and/or turn off petcock valve while not in use, especially before hauling the quad. For newer models, clean and lubricate the choke plungers or replace as necessary.

8) Stock '02 Prairie 650 rear secondary clutch tends to wear out pre-maturely/causes significant decrease in top-speed; Fix: Replace with '03 Prairie 650 or later secondary clutch.

9) Stock actuators for the KEBC and 2wd/4wd tend to fail within a few years; Fix: Some folks remove the KEBC actuator and fork and live without the KEBC function. A few folks have also removed the 2wd/4wd actuator and modified it to function manually via a choke cable set-up. If you don't want to make those changes, you can occasionally disassemble the stock actuators to clean, lubricate and reseal with silicone/gasket maker.

10) Pre-2005 Prairie 650/700 stock rocker arm shafts had mounting bolts on the shaft that could possibly loosen and fall into the top-end of the motor causing catastrophic damage; Fix: Replace with '05 or later model Prairie rocker arm shafts.

11) Fuse box connections may corrode easily; Fix: clean and apply dielectric grease.

12) Stock front diff may break/lock-up, especially if jumping while in 4wd or if one of the oil seals leaks; Fix: Avoid jumping while in 4wd, change the front diff oil as recommended, and keep an eye on the oil seals.

13) Pre-2005 Prairies had a recall on the steering knuckles b/c the original knuckles were prone to breaking; Fix: Contact the local Kaw. dealership to make sure your Prairie 650/700 had the recall work done. You can also look at the knuckle and tell if its been updated or not.

14) 2005 and later Prairies & BF650sra had problems with the stock radiator fan breaker (aka buss connector) which tends to malfunction; Fix: Replace with inline fuse.

15) ANYTHING ELSE ???
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2004 Twin Peaks 700 (sold)
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2002 Prairie 650 (parted out)

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Last edited by Mikeyboy_esq; 07-18-2012 at 02:18 PM.
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Old 07-16-2012, 10:29 AM   #2
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Carburator issues.
1) fuel leaking into the engine past the rings and into the oil supply. Fix: turn off petcock valve and drain the bowls esp before trailering and traveling.

2) Ethanol plugging up the jets. Fix: don't use Ethanol fuel, and drain the bowls after each ride.

Actuator issues.

3) Mud in actuator motors, causing 2wd 4wd indication back and forth. Fix: Don't use the ATV as a jet ski.

4) 4wd actuator aluminum block severly worn and no longer engauges 4wd. Fix: remove the shaft it rides on, machine tap a screw into it and replace with a nylon roller and a washer to hold the roller on..
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Last edited by chopermech; 07-17-2012 at 10:45 AM.
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Old 07-16-2012, 12:12 PM   #3
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Chopermech,
Thanks for the input! They are all very good. However I would have to say that the ethanol issue is not specific to the Prairie. Rather, that is a common problem with all quads and other gasoline powered vehicles.
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Old 07-16-2012, 12:49 PM   #4
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I listed it because it is more specific to the Prairie than the modern bikes due to being Carb'ed
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Old 07-17-2012, 08:52 AM   #5
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Anyone else have suggestions to add to this list?

Once the list is complete, I'll make this thread a sticky. Thanks.
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Old 07-17-2012, 09:09 AM   #6
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Fuse distribution box wires easily corrode.

You covered everything else I could think of.
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Old 07-17-2012, 09:53 AM   #7
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Thanks Jakedogg!
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Old 07-17-2012, 02:11 PM   #8
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Chokes tend to get sticky causing flooding.lots of cam's have been ruined by this.polish the plungers and lube them to prevent this.
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Dynatec CDI
750 flywheel/stator
Dalton O/B spring
12 hole Mod
X over intakes
carbs slides are polished
K&n filter
LRD pipe
And a few other KR tricks I picked up along the way
ITP type 7's
ITP holeshot ATR's for the grass
28 inch Mudzillas for DEEP mud
26 inch zillas for mud racing
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Old 07-17-2012, 02:25 PM   #9
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Stumper, I agree...but I think I have that covered in item #7 on the above list. The '02 P650 had the biggest problem with choke springs due to being too weak on that year model. Thanks for your input!
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Old 07-17-2012, 02:39 PM   #10
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Quote: Originally Posted by Mikeyboy_esq View Post
Stumper, I agree...but I think I have that covered in item #7 on the above list. The '02 P650 had the biggest problem with choke springs due to being too weak on that year model. Thanks for your input!
Definetly happens on the newer machines as well. I know of 4 05 and newer 650's that its happened to.
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2007 650 SRA
Dynatec CDI
750 flywheel/stator
Dalton O/B spring
12 hole Mod
X over intakes
carbs slides are polished
K&n filter
LRD pipe
And a few other KR tricks I picked up along the way
ITP type 7's
ITP holeshot ATR's for the grass
28 inch Mudzillas for DEEP mud
26 inch zillas for mud racing
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