Had a new set of wheels installed and a 4 wheel alignment done today.
One thing I noticed on the alignment report is a large difference in my kingpin angles up front. Either something is worn and needs replacing, or something has been bent.

What would cause the king pin angle to vary by more than 5' between L/R on the front wheels. Please note this is not normally an adjustable angle as far as I know.

Also what is the factory standard for this.

5' is less than 1/10 of a degree, manufacturing tolerance could account for this. Could also be slightly more sag in the spring(s) on one side or something heavy on one side of the car. I wouldn't be concerned about it at all.

Edit: KPI spec is 13° 30' +/- 30', left/right error 30' or less

sorry meant a full 5 degrees
Actual Measurements are
Left +8.10 Right +3.6

Wouldn't extra weight or sag increase the number?

That can't be right! If the king pin inclination (or more correctly steering axis inclination, MR2's don't have king pins) was 10° out you'd also have 10° or so positive camber and the wheel would be sitting in about 120mm. This is not possible unless the chassis has been adjusted by a tree.

What I meant was if the car was sagged lower on one side than the other, it would cause alignment angle variances due to the car not being level. But it would go high one side and low the other by the same amount.

What did they say were the actual camber figures you ended up with for the front L/R?

Camber wasn't too bad
L -00.90 R -01.12

Within the 30 minute variance allowed. The camber on my adub is adjustable as well.

seeing some similar figures.
 
my suspension isn't standard though, I have coilovers with slotted holes where the hub mounts. Is it possible that mounting the hub onto the strut at a different angle would also affect the KPI/SAI angle?
 
if i cant find the problem there then i'm thinking
-suspension heights are out
-check that the same springs are in both sides
-bent control arms
-bend chassis
 
does anyone know if the KPI changes when when you have slotted holes between the strut and the hub?

lol thanks for your input.
 
i know its an old thread but it provides some background... i think mines showing 12deg on one side and 7deg KPI on the other with similar cambers to mms78.
 
im wondering if it could be because of the slotted hub mounts on the shocks or if something MUST be bent...

nevermind.... fixed. 
 
I have to say, Ian at IDB rocks!
 
and for future reference, yes the slotted holes on the struts can cause lots of problems when aligning the car and if you have them, it's worth pointing it out to whoever's doing the alignment.