Gen 2: 2006-2007 Removing clutch basket - Page 2 - Kawasaki ZX-10R.net
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post #11 of 18 Old 12-13-2018, 02:36 PM
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Sorry you are having all this trouble, do you have a thread where you talked abotu your clutch issues?
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post #12 of 18 Old 12-16-2018, 06:09 PM Thread Starter
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No clutch issues at all. It was working fine with the original plates even at 35k. I opened it up chasing a noise. A shop owner of a very reputable shop in town said that he thought it was the basket. He wouldn't work on the bike though. Evidently, he was wrong. I'm too old, fat and stiff to be dicking around with this on the garage floor anymore. I'm taking it to another guy out of town who's got some experience with 1st and 2nd gens. He going to give me some feedback and if it's not catastrophic I'll schedule an appointment for him to fix it.
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Have a wheelie nice day!

Winter sucks.
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post #13 of 18 Old 01-11-2019, 01:20 AM Thread Starter
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New info. The starter clutch was bad. Replaced a gear, bearing and something else to no avail. Turns out the crank is bent. No shit. The guys think that the gears on the crank not spinning true slowly beat the starter clutch gear into submission. With the looser tolerances, it made noise. I'm too tired and frustrated to think straight.

I'd much rather fix this one way or another than part the bike out. I can't afford another bike and I've got far too much into this one to just walk away-even though I probably should. I just can't do it. Besides, I can't in good conscience sell it to somebody like this. That's a low class move. So I've got a rolling chassis of Ohlins goodness that I can't ride.

Crankshafts don't bend themselves. The previous owner had crashed it when it was new and I was aware of it. I went over the bike with a fine tooth comb looking for signs of a poor repair, leaks, scuffs, steering stop damage, frame damage, bad shifting-anything. Aside from a ding in the radiator and the occasional scuffed bolt, I didn't see anything. It tracked straight, it shifted properly, it sounded right. Seems that it took a harder hit than I'd bargained for and now I have to deal with it-10 years later.

Have a wheelie nice day!

Winter sucks.

Last edited by Sasquatch; 01-11-2019 at 01:22 AM.
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post #14 of 18 Old 01-11-2019, 02:24 AM
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There's always positives my friend, so the crank needs replacing, this is a ideal time to build that engine into something truly breathtakingly powerful, even if you borrow money it'll be worth that grin factor. Lighten balance & edge the replacement crank, 35k on the engine! I would go big bore with good headwork and cams.................... have you got the idea
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post #15 of 18 Old 01-12-2019, 01:02 AM Thread Starter
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Originally Posted by michael4012 View Post
There's always positives my friend, so the crank needs replacing, this is a ideal time to build that engine into something truly breathtakingly powerful, even if you borrow money it'll be worth that grin factor. Lighten balance & edge the replacement crank, 35k on the engine! I would go big bore with good headwork and cams.................... have you got the idea
You've got a point and I've been playing with ideas. But I don't have the funds and this is a street bike. I need more power above 8 grand like I need a third testicle. For the tight twisties that I like, I don't spend much time way up the rev band.

The last bike I bored out was an 87 CBR1000F. Yes, kids, the CBR has been around longer than you've been alive. I put a 1050 kit with higher compression in and it ran great but it ran hotter than a whore in church. That was always concerning to me.

I was up late last night on the KWS website destroying my financial life with dreams of a built motor. Maybe I'm too old these days but I there just wasn't much appeal for for it on this bike. It would be a hoot for a bit just to scare myself but I think it would make for a shit streetbike. If I had my druthers, I'd magically make my aftermarket stuff fit on an RC51 and go back to one of those. It always comes down to $ and my lack of it.

I'm bummed.

Have a wheelie nice day!

Winter sucks.
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post #16 of 18 Old 01-12-2019, 01:19 AM
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So you have 2 options, rebuild the motor you have or buy in a replacement hopefully with good history. Maybe you can find someone there to take your old motor on exchange. If you were here I would do that for you.
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post #17 of 18 Old 03-16-2019, 09:06 PM Thread Starter
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It's about time to update this thread. I managed to get my hands on a used motor and had it swapped in. During the swap, 2 things were discovered. First, the donor motor had an intake cam with a blown out freeze plug. That caused some interesting wear. The mechanic used my old cam and buckets to solve that issue. Then, it was discovered that my old stator connection was cooked. WTF goes on here? This is the 4th stator I've burned up in this bike. How it even ran is beyond me. I wouldn't go so far as to say this bike has been a shit box but it certainly has it's issues and hasn't been reliable. The mechanic had to cut out melted harness on my old carcass of a bike and solder in new connections. I've ridden the bike and it seems to work quite nicely. It's been 6 months since I had taken the ZX out so it was a refreshing ride. Anyway, I had to update this as it's frustrating to dig through threads that have no resolution. Keep your fingers crossed that this stator lives a good long time.
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Have a wheelie nice day!

Winter sucks.
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post #18 of 18 Old 03-17-2019, 01:21 AM
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At last a happy rider, you had a string of bad luck for sure but this is where it got better
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