Condition monitoring of rotor dynamic is recognized as an advanced preventative maintenance technique for fault-free operation. Faulty bearings in rotating machines may cause severe problems and even untimely breakdowns. This work demonstrates the power of the finite element analysis (FEA) model and dimension analysis technique (DAT) to analyze the effect of the depth and slope angle of surface faults on the bearing contact characteristic. Experimentation is performed to investigate the vibration characteristics of ball bearings. The FEA, DAT, and experimentation show that vibration amplitude is a vital function of surface fault size. The current approach of FEA with DAT reflects their reliability and accuracy for the diagnosis of rotor systems. The present method was found effective in predicting vibration amplitude and defect frequency within acceptable error.