ZX-10R 2006 - Fixing Broken Valve Spring Retainers
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- Опубліковано 14 сер 2024
- I recently did a valve clearance adjustment on my 2006 Kawasaki ZX-10R, and when I pulled the buckets I found a couple of broken valve spring retainers. I received some advice on zx-10r.net for replacing the retainers in the simplest way possible.
I used only basic hand tools, and managed to get them all swapped out with 2008+ valve spring retainers, which are a direct fit and much thicker and stronger. Since the fix, the bike has been on the road for a full year and done 5000+kms.
In this video, I give an overview of what it took to get access to the valve spring retainers, and a DIY method for removing and installing them. For more detailed information, check the service manual and the original forum thread, found at: www.zx-10r.net/...
Extremely informative video - you have come up with some very creative solutions Raymond - thank you!
Thanks again for making this vid, I replaced all 16 retainers on my gen 1 ZX-10R with gen 3 retainers.
I only had a single broken retainer, on the intake side. The bike only has 12k miles and hasn't been ridden hard.
This method works perfectly, although I did have a small blooper where the keepers/collets weren't quite fully seated, and they flew off when I was trying to put the retainer back on.
Like the vid says, for your own sanity, do not let anything fall into the chain hole or any of the oil passages!!
Well I can now confirm that the 3rd Gen retainers are not the solution I was hoping they would be.
Went through this 4 years ago. An intake dropped on my 06 and it was an absolute miracle but I got away with just a broken valve guide and bent valve. I pulled the head and replaced all the retainers with 3rd Gen parts. Hit the road with it again for 14,000KMs and decided I would do another early valve check since I had so much apart the last time..
2 more broken retainers. 1 of them just BARELY hanging on. Another miracle that it didn't drop another valve.
WoW bro! Im halfway pulling out d whole cylinder head.it’s 2am but im bout 2 do that right now.I had sumthing like in mind, but didn’t figure d whole paper towel inside d socket part. Props bro!
Very helpful video. Will do this on my gen 1 this weekend hopefully.
What a nightmare. Question: What exactly is the cause for broken retainers? Is this due to inferior (cheap) parts being used? Or is this a direct result of living at redline for an extended period of time? I have a 2017 ZX-10RR and while I am sure Kawasaki had several improved parts since the 2nd and 3rd Generation, I'd like to know exactly what causes this issue and, would replacing the retainers with brand new at each valve adjustment interval be a cost effective reasonable mitigation?
Great video. Brings back memories of swapping out the retainers in my 05. Anyone who buys an 04-06 it is a MUST to check this immediately! Got mine used with 18k. At around 26k I checked the valve clearance and 4 out of 8 intake retainers were broken up or cracked. There's no way to tell if they're failing other than checking. Or waiting for a valve to drop. I replaced the bad ones and have 73k on it now with no further issues. I read in the forums it was mainly 04's and some 05's but looks like 06's also. Again great video.
So you also put the 08 Retainers in your 06 Zx10? Are you sure it works fine? Iam afraid of its not fitting for the 06. I didnt find anything on forums that the 08 works for 06. Are you sure ?
@@PhilTV100 No I have a 2005. Supposedly the late batches 04 and newer 05's were affected. By the end of 05 they started replacing the retainers with updated ones. All you need to do is just order the current part number for your bike. That's all I did I didn't change the year of the part. They've all been updated at Kawasaki as they show an updated part number. Not 100% sure on the 06's but if they have an updated part number for the retainers Id get them cheap insurance. Like I said I found several that were cracked and bits were just bouncing around under the bucket. Never new it till I checked. Which you should do if not already. It's not like all the retainers were bad just some. You may not have any broken. But if your a rider that bounces off the limiter constantly then I'd replace them regardless. I now have 96k on the engine and I plan on checking again, mainly for valve clearance.
@@steve23464 wow 96k?? And no problems with the gears or transmission or something ?
The Part number of the 06 Retainers are 120090010 dont know if thats a new number. But 120090010 is also the number for your bike 04 05 06 07 all have 120090010 part number... are that the new retainers ?
You also buy the 120090010 for your 05 ????
@@PhilTV100 Yeah that's the one. Its lists the old number crossed out with the new number next to it on the 05 part view. For the 06 listing they just left the old number off. NO problems what so ever. I replaced the fuel pump last summer thinking it was bad but it turned out to be a short in the harness by the radiator! No issues from anywhere else. If you happen to replace the clutch steel plates save yourself a huge headache and just get OEM ones. I replaced mine from Ebay and unknowingly got thinner steels. Gave me clutch issues for months before figuring out the stack height was off. There's 3 thicknesses offered go for the middle part number. I did replace the swingarm from an 08 mainly for looks. The 08 looks way beefier prb the same stiffness. But it was cheap and easy. Was going to do the zx14 caliper swap but could never find them cheap enough. Heard about CBR1000rr calipers 06-10? Same make but a 2 pad setup instead of 4 pads. Very cheap and I'd say an improvement over stock.
@@PhilTV100 Yes
Did you replace all 16 of them or just the intake side? Also, did you reinstall the cams in order to rotate the motor to have cyl #2 and #3 done? Or did you just keep tension on the chain while spinning the crank?
I did all 16. From what I've seen its usually only the intake side that is a problem, but I didn't want to take any chances. I just kept tension on the chain when rotating.
Thank you so much! You helped me a lot with this 17 socket .
teror1sta No problem, glad I could help!
Boy how I wish I would have read up on this problem sooner...
My 06 was recently due for a valve check (24,000KMs). I've seen so many liter bikes go well beyond that without an issue so I was putting it off. Today, at about 24,800KMs, something in the top end broke and it had to come home in the back of a truck. I'm pretty convinced it's retainer related and I'm hoping for the best but since it seemed to be running on 3 cylinders as I shut it down, I have a feeling a valve dropped...
Hopefully not, but it's a really common problem with these bikes. Good luck.
That sucks man. Did you figure out what the problem was?
I was riding with a friend about 3 weeks ago on he dropped valves. Ducati Hypermotard and the belt came loose. It's a horrible sound.
A valve did indeed drop and it was due to a retainer failure. 1 Valve dropped with 3 other intake retainers broken. The Head is at the machine shop and I'm waiting for parts to try salvage the old girl.
You can check out my channel to see videos on it.
Here's the video of the ride and the aftermath...
ua-cam.com/video/udYA3gKkzJ4/v-deo.html
Great video, very informative and love the tips.
Ive got an '06 with 7100 miles on ( yes genuine verified miles on a 12 year old zx10r ) and im considering doing work on it over the winter, valve spring retainers, checking clearance, decat, quickshifter, power commander, servo eliminator, powdercoat wheel, upgrade to ZZr14 brakes etc.
Should i leave the valve retainers for now, or get them replaced and get a clearance check while its open ?
Di Ablo get them replaced now do not ride your bike again before you do this you absolutely do not want to drop a valve at 160mph. I have a 06 with 9.5k on it and just found out about this bs right before seasons bout to start but I am not going to ride mine again before I do this.
I have a broken retainer on piston #2, the same as shown in the video, does that mean that in order to replace the retainer, I will need piston #2 at TDC? or doesn't it matter?
Yes, piston 2 should be at TDC before you pull the old retainer off. If not, the valve will fall down into the cylinder and you won't be able to put the new retainer on.
@@RaymondDowe Wow I'm amazed to get a reply so soon! I currently have the cams and cam chain tensioner removed, is it safe for me to move the crankshaft without either installed? The manual says I can move the crankshaft without the the cams in, as long as I keep the cam chain taught. I'm just finding the manual a bit confusing, but I'm starting to believe that I can't mess up the valve timing if the cams are not installed..
@@0x7FFFFFFFFFFF Yeah, that's right. You can turn the crankshaft, just be sure to keep tension on the chain. This is to make sure the chain stays on and rotates with the sprocket that's attached to the crankshaft. You just want to make sure it doesn't bind up or get out of place and cause problems. Also make sure you don't drop it in, as it could be a pain to fish back out.
You don't need to worry about timing now as with the camshafts out there is nothing to stay in time with the crankshaft. You just need to be really careful when you put it back together that you get it right. Turn it by hand a few revolutions to make sure.
Thank you, I saved this video as soon as I bought my 05 zx10r, and now a year later I'm really glad I did. Just gonna take my time once it's time to put the cams back in, lot of folk saying that the timing starts to want to shift as they torque the cam caps back up etc.
@@0x7FFFFFFFFFFF The alignment marks will shift a little when tension is put back on the chain, but the timing doesn't really change. The chain is on sprockets on the crank and cams, so unless it skips a full tooth somewhere, that's as close as it gets.
How many KM's does your bike got and how important is it to replace these retainers? I did my valves 2 weeks ago and unfortunately I heard about these retainers recently. I did my valves at 28500kms and did not notice the same wear on the retainers you have.
I did the work around 28,000kms, bike now has about 41,000kms. Hard to say how risky it is. If a retainer breaks and drops a valve, it would destory most of your engine. On the other hand, I had two broken and it will still running fine because they held together. If yours aren't broken they might never have an issue.
Hey Raymond, did everything work fine after that???
Can the complete 08 head be swapped to the 04 zx10?
were all the lower retainers ok, or was it just the uppers that crack?
moforockband Not sure what you mean by upper and lower. The exhaust which are closer to the front of the bike were all fine. The intake is closer to the back, and that's where 2 were broken. From what I've heard, they're more problematic. Not sure why.
I'll just sell my bike now before this happens. I'll go with Honda
This blows 😢