Common Mechanical Problems of the BF750i/650i - Kawasaki ATV Forum
Kawasaki Brute Force/Prairie/Bayou Kawasaki's strong and reliable utility ATVs

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 115 Old 07-16-2012, 10:40 AM Thread Starter
Super Moderator
Feedback Score: 4 reviews
 
Mikeyboy_esq's Avatar
 
Join Date: Aug 2003
Location: Conroe, TX
Posts: 9,413
Lightbulb Common Mechanical Problems of the BF750i/650i

Thought it might be helpful to make a list of the most COMMON mechanical problems/weaknesses that occur on the BF750i and BF650i. (NOT including the BF650sra b/c that is a separate list). This list could be helpful for new BF 750i and BF650i 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.


BRUTE FORCE 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 and rear shocks are too soft for fast-paced riding; Fix: replace with aftermarket shocks

3) Stock CDI is very restricted on carb'd models; Fix: replace with aftermarket CDI to eliminate low speed and top speed retarded ignition timing and to increase maximum ignition timing

4) 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. Some folks install a fan switch and operate the fan continuously during rides.

5) Stock bushings on front and rear a-arms wear out fast/have no grease zerks; Fix: Replace with aftermarket bushings

6) 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.

7) Stock radiator fan breaker tends to malfunction; Fix: Replace with inline fuse.

8) Pre-2007 BF750i stock front a-arms cause hard steering; Fix: reduce castor angle or replace the upper and lower the stock a-arms with later model BF750i a-arms.

9) 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.

10) 2007-10 BF750i rear differential ring and pinion locking nut sometimes comes loose; Fix: Apply red loctite to the nut and torq to spec

11) Stock Airbox intake snorkel needs better splash protection to prevent water from entering the airbox during shallow water crossings; Fix: Install EHS Mudder Lid or install full snorkels.

12) 2005 & 2006 BF750i had buss connectors that would sometimes cause odd electrical problems; Fix: Cut the wires and solder all the white wire together and all of the black wires together.

13) Stock tie rods bend too easily; Fix: Replace with stronger aftermarket tie rods.

14) ANYTHING ELSE ???

2007 KFX 730 (sold)
2004 Twin Peaks 800 (sold)
2003 Prairie 650 (parted out)
2002 Prairie 650 (parted out)

Happy trails...

Last edited by Mikeyboy_esq; 09-25-2012 at 08:54 PM.
Mikeyboy_esq is offline  
Sponsored Links
Advertisement
 
post #2 of 115 Old 07-16-2012, 10:44 AM
Member
Feedback Score: 0 reviews
 
Snyiper's Avatar
 
Join Date: May 2012
Location: Southern MD
Posts: 61
Now haven't most of these been addressed with the 2012 models?

Glenn

Gun Control is never having to say "I missed you"
Snyiper is offline  
post #3 of 115 Old 07-16-2012, 10:54 AM Thread Starter
Super Moderator
Feedback Score: 4 reviews
 
Mikeyboy_esq's Avatar
 
Join Date: Aug 2003
Location: Conroe, TX
Posts: 9,413
Possibly, but I would still like to complete this list for all of those who already bought and/or are considering buying in the future a pre-2012 model BF.

Thanks.

2007 KFX 730 (sold)
2004 Twin Peaks 800 (sold)
2003 Prairie 650 (parted out)
2002 Prairie 650 (parted out)

Happy trails...
Mikeyboy_esq is offline  
Sponsored Links
Advertisement
 
post #4 of 115 Old 07-16-2012, 10:56 AM
Senior Member
Feedback Score: 0 reviews
 
Join Date: May 2011
Location: London, Ontario,canada
Posts: 272
Just the poor bushing setups on the front and rear a-arms that have no grease zerks.
Jakesbrute is offline  
post #5 of 115 Old 07-16-2012, 11:43 AM
Senior Member
Feedback Score: 0 reviews
 
TStubb's Avatar
 
Join Date: Jul 2012
Location: Iron River, WI
Posts: 327
The KEBC acting up, I removed my fork and am happy with it The rear brake cable freezing up in winter. Some cable lube and the cable lube tool is a quick fix.

Mikeyboy is the Moose Module assocciated with the CDI or ECU??? , reason i ask is because I have one and it didn't do a thing. Everyone else claims their's is a wheelie monster with one.

Amature/Pro Dirt Machine Rider!
2006 Brute Force 650i
3,000lb KFI, HMF Slip-on, Dirt Commanders & STI Wheels, ITP Hole Shots & Vision Wheels, Ricochet Skids, Moose Power Module, No-Toil Airfilter, Power Madd Hand Guards, A3 Grips, Kawasaki Shock Covers, 2" Reciever, Temp Gauge, Ogio Bag, 2 Kolpin Jrs.
TStubb is offline  
post #6 of 115 Old 07-16-2012, 01:02 PM Thread Starter
Super Moderator
Feedback Score: 4 reviews
 
Mikeyboy_esq's Avatar
 
Join Date: Aug 2003
Location: Conroe, TX
Posts: 9,413
TStubb,
The Moose module (not same thing as Moose brand CDI...which is actually a Dyna CDI with Moose label) is not as good as an aftermarket CDI. The Moose module (or any other brand module) only eliminates the low end retarded timing and does not increase the max ignition timing or eliminate the top end retarded timing.

2007 KFX 730 (sold)
2004 Twin Peaks 800 (sold)
2003 Prairie 650 (parted out)
2002 Prairie 650 (parted out)

Happy trails...
Mikeyboy_esq is offline  
post #7 of 115 Old 07-16-2012, 02:04 PM
Senior Member
Feedback Score: 0 reviews
 
TStubb's Avatar
 
Join Date: Jul 2012
Location: Iron River, WI
Posts: 327
So the CDI gets rid of the rev limiter?

Amature/Pro Dirt Machine Rider!
2006 Brute Force 650i
3,000lb KFI, HMF Slip-on, Dirt Commanders & STI Wheels, ITP Hole Shots & Vision Wheels, Ricochet Skids, Moose Power Module, No-Toil Airfilter, Power Madd Hand Guards, A3 Grips, Kawasaki Shock Covers, 2" Reciever, Temp Gauge, Ogio Bag, 2 Kolpin Jrs.
TStubb is offline  
post #8 of 115 Old 07-16-2012, 02:26 PM Thread Starter
Super Moderator
Feedback Score: 4 reviews
 
Mikeyboy_esq's Avatar
 
Join Date: Aug 2003
Location: Conroe, TX
Posts: 9,413
TStubb,
The aftermarket CDI still has a rev limiter (which may or may not be higher than stock), but that is not what I meant above when I said it removes the top-speed retarded timing. What I meant was that the STOCK CDI retards the ignition timing at idle (upto a certain speed - say 10mph) and slowly increases to a max of 28 degrees ignition timing, then the ignition timing goes down when it reaches a certain rpm or speed (say above 60mph). The result is an ignition timing chart looks like a bell curve.

On the other hand, an aftermarket CDI (like the Dyna CDI) will have a higher ignition timing at idle and reach max ignitition timing sooner (say 33 degrees) and hold that ignitition timing until it hits the rev limiter. The result is that you take-off quicker (assuming you have good traction), have more throttle response in the mid-range and have a higher top-speed (typically 3 to 5 mph more).

Someone please correct me if I misstated anything above...I'm going off my memory from a long time ago.

Thanks,

2007 KFX 730 (sold)
2004 Twin Peaks 800 (sold)
2003 Prairie 650 (parted out)
2002 Prairie 650 (parted out)

Happy trails...

Last edited by Mikeyboy_esq; 07-16-2012 at 02:28 PM.
Mikeyboy_esq is offline  
post #9 of 115 Old 07-16-2012, 03:49 PM
Senior Member
Feedback Score: 0 reviews
 
TStubb's Avatar
 
Join Date: Jul 2012
Location: Iron River, WI
Posts: 327
I've always thought the CDI gets rid of the rev limiter or increases it to a point that it is a risk or possiblity of blowing the motor up, that's why I stayed away. Advancing the timing, does that hurt it at all? And can this be ran with the moose module?

Any one got one for sale?

Just read online you need to rejet with a CDI, well that sucks

Amature/Pro Dirt Machine Rider!
2006 Brute Force 650i
3,000lb KFI, HMF Slip-on, Dirt Commanders & STI Wheels, ITP Hole Shots & Vision Wheels, Ricochet Skids, Moose Power Module, No-Toil Airfilter, Power Madd Hand Guards, A3 Grips, Kawasaki Shock Covers, 2" Reciever, Temp Gauge, Ogio Bag, 2 Kolpin Jrs.

Last edited by TStubb; 07-16-2012 at 03:51 PM.
TStubb is offline  
post #10 of 115 Old 07-16-2012, 04:19 PM
Member
Feedback Score: 0 reviews
 
DaveFroti's Avatar
 
Join Date: Sep 2008
Location: Quebec, Canada
Posts: 53
"2) Stock front and rear shocks are too soft for fast-paced riding; Fix: replace with aftermarket shocks"

Alternative might be using other factory shocks from different ATV manufacturers. I'de be interested in finding out which ones fit our ATVs.
I know the Grizzly front Shocks work for the rears on the Brutes. But are there Any alternatives other then the grizzly and what about the fronts?

thanks Dave F.

2008 Brute Force 750i Metallic Nocturne Blue
- Starting to modify...
DaveFroti is offline  
Reply

  Lower Navigation
Go Back   Kawasaki ATV Forum > Kawasaki ATV Performance / Maintenance / Technical > Kawasaki Brute Force/Prairie/Bayou

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Search tags for this page
2005 kawasaki brute force 650
,
2005 kawasaki brute force 750 problems
,
2006 kawasaki brute force 650 problems
,
2007 brute force 650i problems
,
2016 brute force 750 problems
,

brute force 750 problems

,
brute force common problems
,
kawasaki 650 brute troubleshooting
,

kawasaki 750 brute troubleshooting

,
kawasaki brute 750 problems
,
kawasaki brute force 650i
,

kawasaki brute force 750 problems

,
kawasaki prairie 650 most common mechanical and technical issues and problems
Click on a term to search our sites for related topics.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Common Mechanical Problems of Prairie 650/700 & BF650sra Mikeyboy_esq Kawasaki Brute Force/Prairie/Bayou 92 06-22-2016 08:31 AM
Common Mechanical Problems of the KFX 700 Mikeyboy_esq Kawasaki KFX700 V-Force 53 07-01-2015 10:06 PM
looking at a 09 brute force 650i any common problems or concerns? kenton15 Kawasaki Brute Force/Prairie/Bayou 16 07-26-2011 09:01 PM
3 mechanical problems occured on yesterday's trail ride Mikeyboy_esq Kawasaki Brute Force/Prairie/Bayou 8 04-18-2011 07:06 AM
650i Mechanical Noise 17A Kawasaki Brute Force/Prairie/Bayou 3 11-22-2006 10:52 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome