I figured I would take this video as the "before"... So I have some sort of reference to how much better it sounds when I'm done with the rebuild. I just need money for a gasket set, piston rings, oil, and a torque wrench. Then I can get the work underway!
Tuesday, April 28, 2009
Monday, April 27, 2009
KZ305AE vs. KZ305AE
The Kawasaki KZ305 motor was used in several different bike. It was used in the 305 CSR as well as the EX/GPZ305 sport bike. I now have both the 305 from the CSR version and the 305 from the GPZ version.
Main differences:
Even though these motors are the same in a nut shell, they have a few key differences. First thing is that the GPZ version of the KZ305 twin produces 6hp more than the CSR versions. How? Simple really, the GPZ KZ305 motors were produced with a more aggressive camshaft as well as a higher compression pistons that bumped the bike to 9.7:1 CR compared to the CSR's 9.5:1 CR. Also, on the later GPZ305s the ignition was an seperate electronic ignition where as the CSR used a "points" ingnition system.
My goal:
My goal is to use the cylinder block, camshaft, and pistons from the GPZ motor. I need to figure out how to make the output shaft on the camshaft from the GPZ work with the points ignition on the CSR head cover. In the end, with a good tuning, less restrictive intake and exhaust, GPZ camshaft and pistons, I hope to possibly bump into the 40hp range.
If anyone finds errors or mistakes please e-mail me!
My spare parts GPZ305 motor:
Main differences:
Even though these motors are the same in a nut shell, they have a few key differences. First thing is that the GPZ version of the KZ305 twin produces 6hp more than the CSR versions. How? Simple really, the GPZ KZ305 motors were produced with a more aggressive camshaft as well as a higher compression pistons that bumped the bike to 9.7:1 CR compared to the CSR's 9.5:1 CR. Also, on the later GPZ305s the ignition was an seperate electronic ignition where as the CSR used a "points" ingnition system.
My goal:
My goal is to use the cylinder block, camshaft, and pistons from the GPZ motor. I need to figure out how to make the output shaft on the camshaft from the GPZ work with the points ignition on the CSR head cover. In the end, with a good tuning, less restrictive intake and exhaust, GPZ camshaft and pistons, I hope to possibly bump into the 40hp range.
If anyone finds errors or mistakes please e-mail me!
My spare parts GPZ305 motor:
My Bike
Here is what the bike looked like the day I brought it home (4/22/09).
The first order of business was to remove that horrid looking rack.
The bike is indeed clean. I have traced the origins on this bike and I'm apparently the 6th owner. The funny thing is that the original owner bought it brand new in 1986 and kept it for first 22 years of its life and he apparently kept the bike in tiptop shape. In May of last year (2008) the bike was sold. The person who purchased the bike traded it lieu of a loan payment only 2 months later. The 3rd owner kept the bike in great shape for the year he had it. Then in March of this year (last month) the bike was given to his son as a gift. His son (4th owner) didn't care to get into motorcycles so he traded the bike for computer equipment almost immediately after he acquired it. The next owner (previous to me) traded for the bike on a whim, and quickly realized he wasn't coordinated enough to operate or maintain the bike. He then saw my add offering an Xbox 360 for trade, and he contacted me with interest. Now, a week later, I'm the proud owner of a '82 Kawi 305 CSR B-1.
The first order of business was to remove that horrid looking rack.
The bike is indeed clean. I have traced the origins on this bike and I'm apparently the 6th owner. The funny thing is that the original owner bought it brand new in 1986 and kept it for first 22 years of its life and he apparently kept the bike in tiptop shape. In May of last year (2008) the bike was sold. The person who purchased the bike traded it lieu of a loan payment only 2 months later. The 3rd owner kept the bike in great shape for the year he had it. Then in March of this year (last month) the bike was given to his son as a gift. His son (4th owner) didn't care to get into motorcycles so he traded the bike for computer equipment almost immediately after he acquired it. The next owner (previous to me) traded for the bike on a whim, and quickly realized he wasn't coordinated enough to operate or maintain the bike. He then saw my add offering an Xbox 360 for trade, and he contacted me with interest. Now, a week later, I'm the proud owner of a '82 Kawi 305 CSR B-1.
The Technicals of the 305 CSR
The Kawasaki KZ305 CSR is a rather rare bike in the U.S. It never gained much popularity here because of its small size. It was fairly popular in various parts of Europe. None the less, the age and rarity of this bike makes part sourcing a bit of a challenge. Also, when I say small bike, I mean small. It is quite hard for me to get comfortable on it... mainly because I'm 6'3" tall. I have to sit on the rear, passenger, part of the seat.
Onto the more important stuff. The first 305 CSR was made in 1981 and known as the KZ305 A-1. Also, in '81 Kawasaki made a KZ305 CSR C-1. The only difference was that the C-1 had mag wheels, where as the A-1 had spokes. Otherwise, both bike had 306cc parallel twin engines and were chain drive. The little 306cc produced a whopping 30hp at 9,000 rpm, and a pitiful 18ft-lbs or torque at 7,000rpm. It has a redline of 10,000 rpm. The KZ305 engine is essentially a bored out version of the Z250 engine. The CSR engines used a "points" ignition system and had compression ratios of 9.5:1.
Next we have the 1982 KZ305 CSR A-2, C-1, B-1, and D-1. The A-2 is idetical to the previous year A-1, and the C-1 is identical to the previous year C-1. Now the B-1 and D-1 were quite different as they were fitted with a belt drive system. The difference is that the B-1 has spoked wheels and the D-1 has mags.
All of the KZ305 CSR bikes were equiped with 6-speed transmissions, dual carbs, dual individual exhaust, disc brakes in the front, drum brakes in the rear, and bent back "ape-hanger" style handle bars. Also, all the bikes had a dry wieght of roughly 270lbs.
Onto the more important stuff. The first 305 CSR was made in 1981 and known as the KZ305 A-1. Also, in '81 Kawasaki made a KZ305 CSR C-1. The only difference was that the C-1 had mag wheels, where as the A-1 had spokes. Otherwise, both bike had 306cc parallel twin engines and were chain drive. The little 306cc produced a whopping 30hp at 9,000 rpm, and a pitiful 18ft-lbs or torque at 7,000rpm. It has a redline of 10,000 rpm. The KZ305 engine is essentially a bored out version of the Z250 engine. The CSR engines used a "points" ignition system and had compression ratios of 9.5:1.
Next we have the 1982 KZ305 CSR A-2, C-1, B-1, and D-1. The A-2 is idetical to the previous year A-1, and the C-1 is identical to the previous year C-1. Now the B-1 and D-1 were quite different as they were fitted with a belt drive system. The difference is that the B-1 has spoked wheels and the D-1 has mags.
All of the KZ305 CSR bikes were equiped with 6-speed transmissions, dual carbs, dual individual exhaust, disc brakes in the front, drum brakes in the rear, and bent back "ape-hanger" style handle bars. Also, all the bikes had a dry wieght of roughly 270lbs.
How it Happened
What is a KZ305 CSR? Well, it's a rare, small, motorcycle. I have come into possession of one of these nice little bikes. This is the first real motorcycle I have ever owned. I've been building, repairing, maintaining, and riding Go-Ped scooters and pocket bikes for about 10 years now, but this is my first "real" bike.
I got a rather good deal on the bike. A couple months ago I traded my 2 12" MTX subwoofers and 1000watt Kenwood amp to a friend for a great condition Xbox 360 Elite with games and accessories. I had my fun with the Xbox, but now that it is getting into the nice weather season, I don't want to be stuck inside playing video games. I started looking for anyone who wanted to trade my Xbox setup for a good Go-Ped or mini-bike. I got a bunch of trash offers... more work than worth machines.
Then, I get an email from a seemingly nice fellow saying that he has an actual motorcycle and he would be interested in trading it for my Xbox. I ask for the details of the bike and I get this response:
1982 Kawasaki KZ305 CSR
~6,000 miles
Clean title, no DMV back fees
Super clean and runs great!
I thought wow! This is a deal I cannot pass up. I call the guy and talk business. We finalized the deal and agreed I would be at his house in 2 days to pick up the bike. I started browsing the internet for information on the bike, and I became very thrilled with the fact that I was going to own this bike.
The next day I get a very sad phone call... The person who has the bike attempted a "tune-up/rebuild" and got it done for the most part except for a couple key mistakes. First thing that happened was he "finished" the tune-up and forgot to refill the bike with oil when he was done. He took it for ~1/2 mile ride and when he got back to his house it was "squeaking." I wanted to cry. I went and looked at the bike anyway. When I got there, first I noticed it was ~26,xxx miles... but the bike was in really nice shape for a 27 year old machine. The bike started, ran, and was ridable even though it was making a horrible "clacking noise" similar to a really bad "lifter tap" on a car. I decided this thing would make a decent project so I went through with the trade anyway.
After getting the bike home I noticed a couple more left out details. Such as the fact that old gaskets were re-used on the top end, and the guy used cork gasket material on the left side crand case cover. It leaks oil from every possible place on the top end and the left side case, which tells me torque specs were ignored in combination with bad gaskets. Now that I know the previous owner was inexperienced, I picked up a parts motor from an unknown GPZ305 sport bike for $100.
I have only just begun on this project, so I want to create this blog for a couple reasons. 1) To compile my collected data on this rare bike. 2) To document the build and 3) to make my collected information known to anyone in need. I do posses the repair manual on the '79-'82 Z250 and KZ305, so if you need info or diagrams feel free to email me and I will help as much as I can.
Stay tuned for updates!
I got a rather good deal on the bike. A couple months ago I traded my 2 12" MTX subwoofers and 1000watt Kenwood amp to a friend for a great condition Xbox 360 Elite with games and accessories. I had my fun with the Xbox, but now that it is getting into the nice weather season, I don't want to be stuck inside playing video games. I started looking for anyone who wanted to trade my Xbox setup for a good Go-Ped or mini-bike. I got a bunch of trash offers... more work than worth machines.
Then, I get an email from a seemingly nice fellow saying that he has an actual motorcycle and he would be interested in trading it for my Xbox. I ask for the details of the bike and I get this response:
1982 Kawasaki KZ305 CSR
~6,000 miles
Clean title, no DMV back fees
Super clean and runs great!
I thought wow! This is a deal I cannot pass up. I call the guy and talk business. We finalized the deal and agreed I would be at his house in 2 days to pick up the bike. I started browsing the internet for information on the bike, and I became very thrilled with the fact that I was going to own this bike.
The next day I get a very sad phone call... The person who has the bike attempted a "tune-up/rebuild" and got it done for the most part except for a couple key mistakes. First thing that happened was he "finished" the tune-up and forgot to refill the bike with oil when he was done. He took it for ~1/2 mile ride and when he got back to his house it was "squeaking." I wanted to cry. I went and looked at the bike anyway. When I got there, first I noticed it was ~26,xxx miles... but the bike was in really nice shape for a 27 year old machine. The bike started, ran, and was ridable even though it was making a horrible "clacking noise" similar to a really bad "lifter tap" on a car. I decided this thing would make a decent project so I went through with the trade anyway.
After getting the bike home I noticed a couple more left out details. Such as the fact that old gaskets were re-used on the top end, and the guy used cork gasket material on the left side crand case cover. It leaks oil from every possible place on the top end and the left side case, which tells me torque specs were ignored in combination with bad gaskets. Now that I know the previous owner was inexperienced, I picked up a parts motor from an unknown GPZ305 sport bike for $100.
I have only just begun on this project, so I want to create this blog for a couple reasons. 1) To compile my collected data on this rare bike. 2) To document the build and 3) to make my collected information known to anyone in need. I do posses the repair manual on the '79-'82 Z250 and KZ305, so if you need info or diagrams feel free to email me and I will help as much as I can.
Stay tuned for updates!
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