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Discussion Starter #1
well folks here are the long awated pics
For anyone not familiar with this. this is the early 04 zx-10r generator problem you may have had.... it has been determined here by zx-10r.net that it was only a select few from kawi. this problem has been discussed over and over again. so if your bike sounds like some marbles are in it. here's what went wrong.

The generator has some shim's in it that were wrong and installed apparently in the early months. These shims wear out pretty fast and allow the brushes to rub the sides scorching it and spraying metal in the motor. this metal sludge then gets sprayed into the motor. the motor will most of the time be ok. just needs to be cleaned out. witch is really expensive. so my advice to you would be hit ebay and find a new one. oh witch brings me to my next point. the generator cost $1100 from kawasaki or 1050 from ronayers.com. why do this when you can get a whole motor off ebay for about $1500 or less.... but without further adoo here are the picks. the first are where the generator is mounted
this will show how shit get's in the oil.
 

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Discussion Starter #2
the next is the generator.
 

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Discussion Starter #3
the burnt brushes in the generator.
 

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Discussion Starter #4
and well now that you have seen that here is your next tool.... www.ebay.com thanks drive thru!
 

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Discussion Starter #6
swjohnsey said:
I wonder if oil analysis would pick this up before catestrophic failure?
Ummm im going to go with no....
 

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Discussion Starter #8
oooo yea they are 5200
 

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Wow, that is a catastrophic failure. You can be sure I will be paying close attention to any metal filings in during oil changes.

I must have an early one (#1149). Back when they made 160+ rwhp stock. LOL
 

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Discussion Starter #10
bad news. if i am getting this right. the earlier the vin the more screwed you are?
 

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sczx10r said:
bad news. if i am getting this right. the earlier the vin the more screwed you are?
Yea, I hear what you are saying. I haven't had any problems yet, but I'll be listening closely for the first indication of weird engine noises. If it does crap out on me, I sure hope it doesn'l leave me stranded 400 miles from home. That would suck big time.
 

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Discussion Starter #12
DO NOT RIDE IT! the sooner the shut down the better!
 

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ok, let me see here, my vin is JKA.......A002219, so does this mean i have an early one? Mine is an 04 obviously.
 

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Discussion Starter #14
I dont know... who's got 0001 or is that the one they toasted at the track?
 

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3947 Orange. :thumbsup:
 

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A008814 here.
 

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I think the first few hundred were probably used for internal testing, and then the next few handed over to the press.

whoa AFMEDIC, that is a very early build.... How's it holding up?
 

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Discussion Starter #20
so is it the lower the number the earlier?
 
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