Gen1 Supercharger - Kawasaki ZX-10R.net
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post #1 of 38 Old 02-03-2019, 01:49 AM Thread Starter
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Gen1 Supercharger

I am trying to rebuild a gen1, that has most of a Rotrex kit on it, but really need to source the mounting brackets/pulleys. I am curious as to what pistons would be best, for this already a complete rebuild.
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post #2 of 38 Old 02-04-2019, 08:41 AM
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That looks like an A&A set-up, minus the lower pulley, PTO, and bracket. I don't believe he makes those parts anymore, so you're going to have to come up with your own if you want to finish it. That is the smaller of the Rotrex units, so you'll want to spin it at a 1:1 ratio with the engine... you could go as far as 10% more if you keep the Rotrex oil temps down (add a cooler). Honestly, that size charger was meant to run stock-like compression levels, so any stock or less compression piston will do the job... I'm a fan of Wossner and Carrillo/CP myself. If it's a total rebuild it would be a great idea to have the piston tops and head chamber thermal barrier coated. You would want to add some sort of charge cooling, water/alcohol injection, or race gas if you plan on really pushing it (land speed racing or such), or you'll need to back the tune down a good bit.
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post #3 of 38 Old 02-04-2019, 03:39 PM
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To add: if you find someone to machine you a lower pulley, A&A uses the Gates 'GT2' belt profile for teeth. You can use any smooth idler pulley for the back side of the belt if you can't get one in exactly the right size... if your center-to-center distance is perfect for the belt length you find you wont need an idler (crazy as that sounds, but I've done it).

....and upgrade your fuel system, especially the pump and POST pump filer system! That's usually what kills these things!

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post #4 of 38 Old 02-04-2019, 08:58 PM
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Yup.

2004 ZX10R-few mods here and there......
and even made more Evil by Woolich.
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post #5 of 38 Old 02-09-2019, 04:42 AM Thread Starter
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I have a Walboro255 fuel pump, and Rotrex reservoir w/cooler. I am going to Bonneville, this August, and would love any advice. I bought the bike with a bad engine, and it’s been sitting for 7+ years.. I have pulled the engine and the rebuilt process will start soon. This is an A&A racing kit minus/ bracket and pulleys.
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post #6 of 38 Old 02-09-2019, 04:55 AM Thread Starter
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Upon inspection, the crank sheered off clean, and this worries me. I bought this sight unseen and not from the original owner (Installed S/C kit). I don’t know what happened, but read a blog about bearings being out of spec. A&A had a batch of bearings out of spec, so the axis of rotation was not concentric with other components. So, I don’t know if this is a design flaw, weakness w/engine component or a improper installation.
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post #7 of 38 Old 02-09-2019, 02:17 PM
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Well, add a new crank, valves, pistons, and making a new crank adapter/PTO to the list of stuff you'll have to have machined/buy. Honestly, you're probably better off finding a whole new used/ebay motor at this point and just save those cases for the next project.

A proper crank support -may- have prevented that failure, but it's pretty much impossible to tell at this point what caused that unless you were privy to the running conditions at the time of failure, and happened to have all of said failed parts in your possession. Driving a supercharger of the end of a crank is always risky business without any sort of outboard support. I damaged a bearing on my outboard support once during installation, and it took about 40 miles or so for it to seize up, un-thread the adapter, and sling the pulley down the street. At that RPM and load, it has to be damn near perfect (+/- .0005 kind of perfect). That being said, that's the first time I've seen a sheared crank on a zx10.

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post #8 of 38 Old 02-09-2019, 02:21 PM
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PS If you make it out to Bonneville for Speed Week or BUBs, be sure to drop a line! First round @ Carmen's is on me. :)

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post #9 of 38 Old 02-09-2019, 02:49 PM Thread Starter
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Thanks for all the info and I’m fairly reluctant to reuse any of the A&A hardware. With no information as to what happened, I’m not willing to roll the dice on another failure.Full disclosure, I still don’t have any of the PTO, brakcet or pulleys yet... I was hoping someone on here could source something for me, or send me in the right direction. +\-.0005” seems a bit daunting and I work with true position/concentricity tolerances every day..
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post #10 of 38 Old 02-09-2019, 02:52 PM Thread Starter
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This will be my first time and I expect the worst..
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