Gen 1: 2004-2005 Dropped a valve HELP - Kawasaki ZX-10R.net
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post #1 of 15 Old 04-29-2012, 04:08 PM Thread Starter
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Dropped a valve HELP

Guys hi,

im really sorry if this has been covered already,

heres the full story,

Decided to build a new engine for my track bike ( 05 zx10r )
spec:
stm slipper clutch
balanced and polished crank ( standard rod and pistons )
nova box
block jetted to keep more oil on the crank,
head built to kawasaki race manual spec, ( ported 1mm larger inlet and polished )
kent cams ( kaw 25's ) degree 105, 105 as they request.
uprated inlet valve springs and shimmed exhausts,
2 degree ignition advance
ngk race plugs ( yes the 200 ones )
micron full system
.40 kit head gasket,

Heres the problem:
put the engine through 200 miles soft running and 10/12 heat cycles
tunning on the dyno started well, hp was looking good but then right at the end on the last couple of full throttle top end fueling adjustments .....it let go!
11500 rpms the bucket on cylinder 3 inlet smashed and dropped the valve...as you can imagine i was over the moon :-)
anyway i wanted to ask two things:
1, could i fit the 2006/2007 head to the 05 block as im struggling to find a head? ( i know the inlets are 1mm smaller )
2 is there any other mods or head work that ive missed that work well?
thanks in advance for your help guys
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post #2 of 15 Old 04-29-2012, 06:49 PM
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06/07 head yes, and use 08 valve keepers.
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post #3 of 15 Old 04-29-2012, 06:55 PM Thread Starter
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Hi
do you meen the top spring retainers?
Regards
Peter
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post #4 of 15 Old 04-29-2012, 06:57 PM
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Quote:
Originally Posted by Peterrsv View Post
Hi
do you meen the top spring retainers?
Regards
Peter
yes, sorry, valve retainers .Better design and still aluminum.
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post #5 of 15 Old 04-29-2012, 07:11 PM Thread Starter
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Thanks for the advise Jake
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post #6 of 15 Old 04-29-2012, 07:53 PM
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so what exactally failed? the bucket? or the keeper popped out? or the valve sheered off?
If the keepers are't settled when installing them they can pop out causing alot of trouble.
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post #7 of 15 Old 04-29-2012, 11:01 PM
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What was your piston to valve clearance?
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post #8 of 15 Old 04-30-2012, 07:06 PM Thread Starter
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With all the mess it's hard to say what let go but my guess is the valve bucket broke,
the retainers were Kawasaki kit parts and springs
Valve clearance was 1.2 exhaust and .65 inlet
Head decked .40 mm
Squish .65
The valve stem was bent at the top and the guide was snapped of so it def let go at the lobe end,
I spoke to Kent and they told me the buckets ( valve followers ) are the week point,
They gave me a part number which I gave to my local kawi centre
The number is 98/99 zx7r,
Kent say they are much better than than the zx10r followers and have never had one brake but have had loads of zx10r brake during testing.
What's your thoughts??
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post #9 of 15 Old 05-01-2012, 06:22 AM
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hmmm...have any pics of the failed parts??
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post #10 of 15 Old 05-01-2012, 08:14 AM Thread Starter
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Sorry no,
The bucket was found in a million pieces, the cam lobe is scrap where it rode the keeper and valve tip
the head where the bucket runs has lumps out of it.
I've just picked up a 2007 head complete this morning,
Planning to do the following
Port ( as per the Kawasaki race manual )
Deck to get the comp up,
Picked up a .40 and .50 kit gasket today,
New cam chain ( maybe OCD but could not re build using the same chain after that sort of stress went through it.
Now kent have told me to use the standard springs and retainers as they do,
They tell me as I'm not upping the rev limiter it will not bounce at all
"we always use the standard spring and retainers"
They tell me to use the zx7r buckets
Kent have received my spare inlet cam this morning and are grinding it to kaw 27 spec, it will run with my kaw 25 spec exhaust.
I've been told you can shape the valve stem in the port to reduce restriction
Have you heard of this, is it worth it?
Cheers guys
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