My 2009 Kawasaki Teryx kept cutting out under load and burning oil, so I had the engine rebuilt with 10:1 compression pistons. It still cuts out under load, but only once it warms up?? I ordered an after market fuel pump because the guy who rebuilt the motor said that he found that the fuel pressure wasn’t staying up under load once it was warm. That didn’t work either so should I buy a factory one? I didn’t in the beginning because they are $600 from Kawasaki. The plugs are new when the motor was rebuilt. Any suggestions??

Respectfully, Casey

Hello Casey,

I am sorry that you are having so many little issues with your Teryx. I know it is frustrating. Generally speaking, when most people rebuild an engine they tend to forget crucial items in the whole picture. One item that gets neglected is the fuel source and lines connecting the engine to the fuel source.

If it were mine, I would eliminate small items starting with the fuel tank by removing it and completely cleaning out the interior. I know this would have been easier before replacing the engine, but maybe just removing the fuel pump assembly will give you enough room to get it really cleaned out. The fuel pump screen is also an issue sometimes, so be sure it is either very clean or new. This may or may not be the problem, but it’s a great place to start.

Once the fuel source is cleared be sure the fuel lines are all in good shape and not showing any signs of degrading age or chaffing. I have also heard of the fuel line “quick connects” (your Teryx has two I think) leaking just a little due to faulty or aged o-rings inside them, which could reduce fuel pressure to the engine under load.  Replacing the o-rings or simply removing the quick connects and adding hose clamps will eliminate this possibility. You should measure the fuel pressure with a good FP Gauge both when cold and during its warm cycle to determine the pressure you’re getting. Using an OEM service manual for all of the correct measurements is also crucial to getting good information.

One last item that sometimes reveals its issues when warm is the ignition coil. Usually these will begin to misfire as they heat up. Just keep in mind that eliminating one small potential issue at a time is the same thing a dealer would do, so if you have a little patience you might save yourself a pile of cash. Let us know what you do find and we wish you luck.

RS

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