What's that NOISE? 2004 zx10r project, Part 7. Is it the clutch or even worse, the generator?

It's no good, Dave can't ignore the noise any longer. The ZX10r has a rattle, it might be nothing much or it could be the dreaded generator fault. There's only one way to be sure, take it apart and have a look inside.
Dave takes apart the clutch and the generator to see what's causing his paranoia

[@MrPADDYOT]

Dave you really do put the 'obsession' into Obsession Engineering. Wish every owner went into this level of detail and care with their machines.

[@jayclarke1421]

This is the most helpful video I’ve seen on gen1 zx10. I basically bought a bike I can’t fix bcuz parts are extinct now. I live In The states and this bike is almost nonexistent.

[@aldo5658]

I heard this but I didn't believe it 😢 that doesn't even make sense, why would Kawasaki cease making parts for a legendary bike 😩

[@2wheelfamily493]

You can take the generator and clutch basket off a 2005 zx10 and it's a straight swap to your 2004 zx10 just have to make sure the generator and clutch basket come from the exact same 05 bike.

[@stephenstead7852]

Cheers Dave. Very informative for us mere mortals that ride old school road bikes.

[@aldo5658]

Such a helpful video, thanks mr obsessive engineer for all ur videos. Helps me been able to work on my bikes for reference and understand more regarding my motorcycle 🏍️

[@davidpalin1790]

Always fancied one of those bikes I have a 2003 ZX636R

[@obsession_engineering]

I have a b1h as well, worth keeping just for the induction noise

[@IljoWRC]

@@obsession_engineeringcouldn’t agree more

[@steve23464]

3am and Dave puts out a video. Well let's go..

[@dxc12345]

You put on the vinyl. Matches pretty well

[@2wheelfamily493]

You can take the generator and clutch basket off a 2005 zx10 and it's a straight swap to your 2004 zx10 just have to make sure the generator and clutch basket come from the exact same 05 bike.

[@obsession_engineering]

👍🏼

[@bushbiaggi]

You are so funny 🤣👌 Proper explanation 👍

[@jimarillo]

Crisps Dave ! That’s some detail, thank you. Also great explanation of a clutch too, thanks

[@angry2895]

Hi dave good video i have done this job a couple of times, had the same paranoia, with your drive gear being a C you wont find a suitable 2005 replacement, there none of that gear on the C2 parts list i did get an a complete generator off a C2 but the gears did not match so sold it on but i did do the shim check, seems a big tolerance for such a high speed gear.

[@johndejager5673]

Probably a stupid question but what might go wrong when gears 2004/2005 are mixed. Generator gears 2004 and 2005 look the same...

[@obsession_engineering]

If the gears are coded the same, it's no problem, but if the coding is different there won't be the right backlash to allow for expansion so it'll either wear fast or just not fit.

[@johndejager5673]

With the Gen1 2005 model Kawasaki solved the generator problem, it fits right in.

[@obsession_engineering]

Except finding one is awkward and finding the matching clutch basket makes it even more awkward again

[@johndejager5673]

@@obsession_engineering What can go wrong when mixed? I have 2004 "C" basket (13095-0034) and 2005 "A" generator (13095-0033), or should I fix the 2004 generator?

[@davidshield260767]

Kawasaki workshop manual... 1. Remove part 'A' (see note 2) 2. In order to remove part 'A', first remove parts 'B, C & D' (see note 3) 3. In order to remove part 'B', remove parts 'X, Y & Z' (see note 4) 4. In order to remove parts 'X, Y, Z & C' remove part 'D' (see note 5) 5. In order to remove part D, remove engine from frame, strip suspension & chassis (see note 6) 6. Shout at bike angrily, then apologise ZZR owner ;-)

[@obsession_engineering]

Yeah, pretty accurate 🤣

[@Bow-to-the-absurd]

Oh that's it exactly. Disgustingly packaged machines

[@trackdaylbs]

Videos are great Dave. Really enjoy these. 👍 Clutches... how much of my track time has been ruined with clutch and gearbox issues... 😭

[@presstodelete1165]

I suspect you stole the cheese and just blamed the mythical mouse!

[@obsession_engineering]

I do like cheese :)

[@yotiep.1072]

So where does the clutch fluid go?i have an 04 zx10r..please let me know thanks

[@cbrblade2705]

I hope it was that, rather than the dreaded valve spring retainers cracking or even shattering, had to do my mates zx10r 2012, after his cam turned in to chocolate and then cracked a valve spring retainer and dropping a valve, ouch. cost about £600 in parts and under pants.

[@chrislee7817]

Hi Dave did I spot a witness mark at about 11 o'clock behind the clutch basket? About 14-15 mins in on vid. I hope it was a machining mark.

[@SB-Kiwi]

Hi Dave, hope you're feeling revitalised after the TT. A quick question. You mention in this upload that one can put less of the spring washers/leaf springs in when reassembling the clutch. My 04 is tack only. Would you recommend this as a track modification? Thanks.

[@obsession_engineering]

Of you'd like more slip on corner entry it is a nice easy mod

[@SB-Kiwi]

Thanks, Dave! Do I need a shim in there in place of the spring or is it OK without?

[@nitramh24]

Wow! This is amazing! Straight up, no non-sense knowledge for old Kawasaki-fanboys like me... Not to sound like a smart aleck, but wouldn't it have been easier to drop the engine in episode 2 and do all these fixes from the beginning😂?

[@obsession_engineering]

It wouldn't have been far off, just didn't know then how far I'd have to go

[@Pleva_Peter]

Dave, according your video you did not repalce any component. You just disassembled that and put everything back. Is this mean that you solved the issue? .. I´m little bit aware of this repair and I don´t know which parts I will need to fix this "clutch or generator noise".

[@obsession_engineering]

It still makes the noise and I'm still looking for the correct clutch basket. But I do know I don't need to worry about it too much

[@Pleva_Peter]

@@obsession_engineering thanks for response. I will check clutch and generator just for sure.. Because I hear some vibration sound from clutch area.

[@bigjam8429]

Couldn’t you stretch the basket springs so it would take up play and stop rattle ?

[@obsession_engineering]

No, they spring back!

[@jumpsuiit]

Hi! Do I push the alternator shaft all the way in until it stops after engaging all the secondary tooth gears? If its all the way in, the gears are 2-3 mm further than the clutch housing gears. Or do I adjust it to be exactly flush with the clutch housing gears? Hope you understand what I mean 😅

[@papapanda4525]

Hi are you able to assist me please, I have a Leak ont be clutch cover are you able to advise of the order of the bolts and torque settings for me please? I would appreciate it 🙏🏽

[@obsession_engineering]

I tend to do the bolts up in opposites, bit by bit. They should be 12nm but done up in 2 or 3 stages. If you change the gasket, make sure to get all the old gasket off both faces, as any old gasket can hold the cover off

[@papapanda4525]

@@obsession_engineering thanks a mill love your video, happy new year from South Africa.

[@stephenmcqueen4029]

Weld the springs onto the clutch plate?

[@jandzban8778]

Hi. Why didn't you show the sound of the engine before and after the repair? Did the clutch basket rattle at idle?

[@obsession_engineering]

It did! I'm keeping an eye out for a better basket still

[@jandzban8778]

​@@obsession_engineering I decided to send the basket for regeneration. It's in progress. The company will make new elements for me. They have many satisfied customers. I hope to be next!

[@troywee4774]

excellent, it is a bit of a faff for sure! cheers.

[@931PORSCHE]

Was the generator issue just in the 04s and what year did it get fixed that would be a option for a replacement?

[@obsession_engineering]

They updated the parts for 05. Unfortunately there's no other real upgrade options apart from the 05 parts, that are no longer available

[@931PORSCHE]

@@obsession_engineering ok thank you i pretty much go for 05s cause of the magma red color and Iv heard bout the clutch basket issues and i think it was valve spring retainers being the 2 big catastrophic failure points. But not this issue. Awsome video definitely going go through the rest you have on the 1st gens they are my favorite bike.

[@icklepob88]

2 ugga duggas on the clutch nut 👌

[@bikeislifemikigarage1089]

Ciao dave,scrivo dall'italia e ho uno zx-10r del 2004 e ho questo rumore anch'io,volevo chiederti nel controllo del generatore hai verificato anche gli smorzatori in gomma dietro all'ingranaggio silenziato?in che stato erano?grazie e gas!✊✊✊

[@obsession_engineering]

Mine were in good condition luckily. I'm still on the look out for a good clutch though

[@SWTMotoVlogs]

So you have any email or media to send the vedio of my gen1 i did not recognise the sound

[@jumpsuiit]

Hi Dave! Great video! I just did this check now. I removed the clutch basket also but notice that my center bearing or bushing that you put in at around 16:25 in the video, refuses to go in from the front.. even with the clutch basket on a table it only goes in from the back! That is so strange. So now i cant put it back inside the bike . Any ideas?

[@obsession_engineering]

Very strange, assume there's a Ridge worn on the front as I'm sure it should go from both sides. Worth a look!

[@jumpsuiit]

Solved it! Thanks for the reply.

[@Bow-to-the-absurd]

Always hated working on my 636 Everything is designed to be as awkward as possible. the inaccessible battery is inexcusable.

[@karlvanboxel561]

Years ago I sent my gsx1100 clutch basket off to an engineering company that put a heavier backing plate in the basket with new springs and attached with new rivets prob solved

[@Phil-jh7qr]

Great video series the amount of times I had to drop the engine and split the crankcase to get at the gearbox on my old 05 racebike isn't even funny including at an actual race meeting but to be honest I now know nearly ever every bolt on one of these Also I have a spare clutch basket still ill check the spring condition if your looking to replace

[@obsession_engineering]

That'd be great, thanks

[@unclemel3607]

Hi dave happy to see the old 10 getting the love it deserves am curious as to haw many kms this one has traveled? would you know wether the 05 c2 has the generator problem also ? my 05 is still running like a champ at 65000 km gets well maintained my mechanic mate who maintains it says its due a clutch, plates are thin but no rattles or slipping. he even has a new clutch basket lying around for a c2.

[@obsession_engineering]

The c2 had a modified generator so no worries there. Some clutches seem to wear quicker than others, my original 04 race bike had to have a new basket after about 4000 miles, but others last to very big mileage. If yours is going strong at 65k I think you've looked after it well and probably won't have big problems

[@shanemcredmond9751]

Happy new year Dave. I was surprised to hear these parts are no longer available. I mean, the bikes not that old. Is this a Kawasaki thing or is it common with other manufacturers too?

[@obsession_engineering]

Pretty common. I think they have to supply all parts for 10 years, then they'll only keep making the parts that make enough profit

[@shanemcredmond9751]

@@obsession_engineering Cheers Dave 👍

[@stevesanelli90]

Again a great description & work involvement Dave! Damn time consuming & what a faff. Will you be rebuilding the rear shock & cleaning up the rear end? Stay safe & healthy ⭐️

[@missydee6085]

kzbin.info/www/bejne/q32tm5SDrNRgh9U 👍

[@eds4947]

Makes me feel a bit paranoid about stuff going wrong with my 04 and not being able to find the parts to get it fixed!

[@johnpaice8481]

Hi on a sump cover gasket on a honda (vfr750 ) sorry I know this is a zx10 vid , would u use any gasket cement or dry or grease .....thanks .

[@obsession_engineering]

If it's got a gasket, a smear of grease or dry, no sealant.

[@johnpaice8481]

@@obsession_engineering thank you ....

[@vaughandavey4553]

I didn't know about the crash bungs - I mean you didn't say a single word about them in that first episode😜. Do you have a problem with them?🤐👺

[@obsession_engineering]

😂

[@stephenbooty3773]

My local Kawasaki dealer seemed to pluck a figure out of thin air to complete a valve clearance check… I will be completing it myself.

[@obsession_engineering]

They don't usually move much either, but nice to check for peace of mind.

[@user-lu6ht4sg2u]

Im in pa there is a guy that will rebuild that alternator its called k&m electric hes in east berlin pa

[@motorcyclegarage2307]

Put some EP90 in it.

[@prozeza]

Dave, this German (I think) fella has an excellent fixing-bike-stuff channel. He has a video fixing rattly clutch basket springs: kzbin.info/www/bejne/g3S2kpmBnNmpbMk&ab_channel=PaulX