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Servo's Eliminatus ;)
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Discussion Starter #21
good on you.
dont know if any of you know but in europe ,2-3 years ago ,suzuki had a recall on 05 gixxer1000s with cracked frames. as it goes. it was a friend of mine who started the ball rolling as his frame cracked in 3 different spots and he wrote and to suzi in japan with his mechanics autherisation and pics etc etc. . suzi gave in and he had a new frame and about 7000 other k5 owners in europe. all his correspondence is framed and hanging in his lounge lol:cool:
i will be checking my frame tomorrow :-
I take it you found no cracks in yours?
 

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Johns04zx10 i hope kawasaki either replaces your frame or at least repairs your chassis in the corect manner .being the bike wasnt in an accident ( or looks not to be ) a crack of that magnitude is likely caused by a design flaw or bad weld .
 

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This is the first ive heard of cracking chassis in the zx10 line.
I was under the impression the cracking problems where found only in the zx14 monoque type chassis.
 

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Yeah unfortunately I have seen a couple bikes with this same problem personally and a lot more on this forum with the exact same problem. My bike is 7 years old with 30k miles, so I dont really expect Kawi to do anything about it. I just paid my buddy $60 bucks to have it welded. If it continues to crack I will just buy a new frame for $600 bucks. I love the bike and have definately got my money's worth out of it.
And yes my bike has been crashed at about 10mph by an inexperienced friend of mine. He hit some gravel and lowsided it; his wrist put a small dent in the frame which is pictured above. The frame was not cracked at that time and it went another 10k miles before the cracks developed. Im not too worried about it.
 

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John i forget how much used bike prices have went down as of late due to the economy. You are taking the best route . Btw 10mph...crashes..?? Do not count lol
 

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Servo's Eliminatus ;)
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Discussion Starter #28
The best route for fixing the bike financially is to weld it up.
If you take the bike to kawi, they are gonna charge you for inspecting it,
and when kawi denies you a new frame for whatever reason they want,
Your gonna be responsible for the bill.

My wifes cousin is gonna let me use his shop and aluminum welder to repair mine.
 

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Hellsrazor. My good friend is the chief mechanic at a fairly large trucking company thay hauls dry bulk.( which always run maximum weight of 80k)
the trailers are all aluminum and being they run max weight all the time , they crack and need to be welded frequently . I will ask him to conferm this but if recall correctly he would drill a small hole at each end of the crack so it wouldnt spread...weld crack and grind flat .... Then weld a aluminum plate over the crack with the plate covering roughly 1/2 inch over each end of the crack. I will ask him if he refills the smalls holes at the end of the crack and if you should plate both sides (if it is possible you can get to both sides of frame )
 

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Servo's Eliminatus ;)
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Discussion Starter #31
Hellsrazor. My good friend is the chief mechanic at a fairly large trucking company thay hauls dry bulk.( which always run maximum weight of 80k)
the trailers are all aluminum and being they run max weight all the time , they crack and need to be welded frequently . I will ask him to conferm this but if recall correctly he would drill a small hole at each end of the crack so it wouldnt spread...weld crack and grind flat .... Then weld a aluminum plate over the crack with the plate covering roughly 1/2 inch over each end of the crack. I will ask him if he refills the smalls holes at the end of the crack and if you should plate both sides (if it is possible you can get to both sides of frame )
My buddy did the same thing to mine. He said drill the ends or the crack will keep running.

You are correct about drilling stress relief holes at the end of each crack.
I already have plans for that before I weld it up.
Now the plates will not work where I have to weld mine,
it would get in the way of the motor mount.

I'm going to invert the frame and weld it down hand to
keep the heat localized.
And I think that should be plenty good enough to hold it.
Hell, if it happens again down the road from me riding it like I stole it,
I'll just weld it up again.
 

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I called friend who welds stress cracks on aluminum dry bulk talks . He said to weld the holes at the ends of cracks . Then grind out the crack itself . Then weld a plate on backside over crack. Next grind plate where crack has be grinded(not through the plate but deep enough for weld to grab ahold of ) then weld both th ground out crack and the plate behind the crack.

If you cant get to the backside of the crack. Drill holes on each side of crack. Refill with weld grind out the rest of the crack- weld and smooth . Then weld plate on top of crack/weld . I hope this helped as my teaching skills are lacking lol.
 

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Servo's Eliminatus ;)
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Discussion Starter #34
Ok everyone, if you have not submitted your information yet, you need to
Because Friday January 27th, all information is being submitted to Kawasaki's USA
and JAPAN.

So, now is the time to act.
 

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Hey,I'm new 2 the forum,i have a 04 zx10r with major cracks,2nd owner 12k miles never crashed, I'm tryn 2 join your group on Facebook thru my wifes page
 

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Servo's Eliminatus ;)
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Discussion Starter #37
Hey,I'm new 2 the forum,i have a 04 zx10r with major cracks,2nd owner 12k miles never crashed, I'm tryn 2 join your group on Facebook thru my wifes page
I will add you if you request it on f/b

Is it true u have 2 b the original owner n the bike can have no mods???
Yes it is true. Unfortunate but true.

I am extending the deadline to this Monday.
So that a few more people can join.
Get your names in.
 

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Some Hope for Those that Bought Used

I'm the second owner of my bike & Kawasaki coughed up a frame. But, they weren't willing to pay for any labor, so I'm doing the whole thing myself.

The dealer said that Kawasaki gave the frame because my bike was super-clean & they wouldn't consider it if there was any sign that the bike was crashed. All that said, the dealer sent photos to their rep at Kawasaki & they got the approval for my frame the next morning.
 

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