Was just curious if the Front Diff is the same between the Prairie 700/BF650 and BF650i/750i. For 2006, all four of these units appear to use the SAME front diff parts as far as I can tell (To be fair, I didn't actually check every single p/n to confirm this, so I could be wrong about this).

While I was searching P/Ns, I also checked the P/Ns for the 4 Front Diff case pieces (LH Case 14057-0014, RH Case 14055-0014, Center Case 14055-1155 and LH Bevel Case 14055-1156) and compared them to differen year models. Here's what I discovered...

The 2002/2003 P650 and the 2004/2005 P700 use a different RH Case (14057-1149) than the same part found on the 2005/2006 BF650/BF750 and the 2006 P700/BF650i (14057-0014).

This RH Case just happens to be the same exact part that broke into 2 pieces during one of my races last year (probably from landing BIG MX style jumps during the Maxxis 6 hours of TX Race). That is good news b/c I'm guessing Kaw beefed up this piece for the newer Prairies/BFs and hopefully this problem won't happen as often in the future. I'm not sure if the rest of the parts in the newere Prairies/BFs are the same or different than the older models...but I suppose its possible. I sure hope this means less front diff problems in the future!!!

Happy trails...[img]i/expressions/face-icon-small-smile.gif[/img]

 

Kawi folks didn't really beef up the gear case even though the P/N might have changed. If you broke the gear case by outside impact, there isn't much solution for that. However, if the gear case broke (busted out) due to internal gear failure such as spider gears seizing onto the 4" shaft and broken metal pieces jamming between meshing gears, you can prevent it from happening again by following 2 simple steps.
1). Make a groove or slit on the shaft so that oil can flow better.
2). Use synthetic oil in the front diff gear case - Never use hypoid gear oil.

 

My cousin recently purchased a 06 bf650 sra. We went to pick it up from the dealer today. My cousin had takin it up there for a broken cv joint, right front outside boot was severely twisted, showing a definate broken cv joint. Well any way the dealer called and said it was ready but as usual that was not the case. When he dropped it off he told them about the cv joint and told them it was extremely hard to turn. Come to find out they fixed the cv joint. Also tried to charge him $130 for a cv "boot pack" service manager said they couldn't get 1 cv boot they had to get a whole pack obvious B.S. My cousin called me and I told him I would ride up there with him. Now I'm not a kawi certified mechanic but I've been around them a time or two and because of me that shop has sold 6 bikes I can think of right off the top of my head. Any way I went to give them hell about the $130 cv boot B.S. and come to find out the bike isn't fixed. Sure they replaced a cv joint "wow" but didn't even look at the hard steering. Come to find out the diff lock lever didn't work and after they drained the front diff fluid, while we watched by the way, it was full of shavings and a piece or two pretty big probably gear pieces IMO. Well the owners son who basiclly runs the place was out there and said he thought it was just the diff clutch bundle. I told him I though it was the gears and when they get it torn out and apart we'll see. Anyway to you thread. My 700p has 2500miles of racing, wheelie riding, and general use and abuse with no prob. IMO if anything this one was a defective unit or kawi is making them a little weaker. I hope not cuz the market wont allow for poor quality or workmanship, not today, not with so many other quality choices out there. Now I like the owner and his son. Hell I even like the mechanic. But that B.S. service manager is about to cost them alot of money in my and my freinds and familys business. I'm gonna let the owners know one more chicken **** deal like the "boot pack" and that'll be the last time they ever get any money from anyone I know. Sorry for such a long post [img]i/expressions/face-icon-small-smile.gif[/img]

 

Like I said, that's exactly what happened to your cousin's bike. The spider gear seized to the shaft and broke inside the front diff gear box. That's why the bike had stiff steering due to no differentiating inside the gear box. It was acting like a solid axle before it broke. Use synthetic engine oil when rebuilding the gear case so that it doesn't happen again. Better yet, modify the shaft as I described above.