03 650 prairie
My front motor mount is egg shaped. The problem started when it was new. The front brackets were welded on the frame to far apart. I have had it back to the dealer 4 times and kawasaki doesn't want to replace the case. The hole is double it's size and It keeps jumping out of gear where the motor shifts up and down. I have extended warr. I am going to try am going to try and get them to fix it again. the only proper repair would be to replace the case. If they dont fix it I am going to take them to court. I would like to use some of these post in my behalf. Thanks

 

THE SAME THING HAPPENED TO MY BUDDYS 02 P650 HE ALWAYS SAID HE WAS CONSTANTLY TIGHTENING UP HIS MOTOR MOUNT BOLTS. I DONT KNOW IF KAWI DID ANYTHING ABOUT IT , CAUSE HE DID NOT HAVE EXTENDED WARRANTY. IF YOU HAVE EXT. WARR. THEY SHOULD TAKE CARE OF IT . DID YOU CHECK ALL THE BOLTS PER OWNERS MANUAL? IF I REMEMBER RIGHT YOU ARE SUPPOSED TO CHECK THEM AFTER A CERTAIN AMOUNT OF TIME TO A TORQUE SPEC. I CHECKED MINE WHEN MY BUDDY FOUND HIS LOOSE, MINE ACTUALLY WAS A LITTLE LOOSE I CRANKED IT AND NEVER HAD ANOTHER PROB. BYPASS YOUR DEALER AND GET A HOLD OF A FACTORY REP. SOMETIMES THE DEALERS JUST BLOW YOU OFF! GOOD LUCK![img]i/expressions/face-icon-small-shocked.gif[/img]

 

Guess I better check my my mounts.................

 

I have had trouble shifting for over a year now and just befor christmas i jacked her up and removed the belly pan. yep she needed the front motor mount tightened allright. still could not get the shifter right so i broke out the file and did some minor adjustments to the shift rack. the front motor mount is a vary bad design. if i have to fool with it again i think i will pour it full of liquid rubber.

 

I have always tried to keep all the bolts tight. After it started it continued to get worse even tightening after every ride. Liquid rubber sounds good. If I cant get it fixed I could take it down to the tire recap shop and have it filled.
The mount is hollow inside with about 1/2 inch of aluminum on the edges.

 

Mine was loose and I tightened it to the 45 ft lbs like it said and that did not hold.The next time I just CRANKED it down and so far so good.Some people say to loctite it but thats not the problem.The block is wearing where the frame ears are.It looks like the bolt should be the same diameter as the hole in the block???? that would keep it from moving up and down.Someone on here said the dealer enlarged the holes on his frame ears I believe so they could use a larger bolt and that solved his problem.I think it was DOA or someone else.......
02 650 camo

 

Mine was loose, tightened it then haven't had a chance to ride the quad much since so not sure if it'll stay tight. The bigger bolt idea sounds like a good one tho.
It looked to me like the initial loosening of the bolt was due to the fact that after it was originally torqed up, and I'm sure just thru normal vibration, etc, the paint on the frame ears cracked/rubbed away. The paint seems fairly thick, so this would leave a bit of a gap. On mine, the paint was completely gone off the ears where the bolt and nut contact them.

 

Yes, it was me that had it fixed (under warranty) and has held for over 2500kms.

They drilled the whole unit I believe to make it solid contact, then put a MUCH bigger bolt that was torgued heavily as well.

You can phone my dealer for more info if you wish, Blair Brothers @ (902) 895-8209 tell them it was Darrell's bike to reference them.

 

the hole in the eng case is double the size of the bolt. It looks like you could put 2 bolts in the hole.
It would be nice to have a metal lathe where I could make a bushing. it looks like I would have to drill it out to 3/4 inch to make a round hole again.