Tips and trics

Tips and trics

Buy yourself a donor machine. It is very handy, safes you a lot of travelling to the dealer. The right engine is a chopper unit. No parts are equal to the GPz. Only the gearbox and the clutch. But that are parts which never fail.
The camshaft is sensitive for good oil. This is the spot, oilchains break and are destroyed by the the high forces of the revolutions. Change the oil frequently. Freaks change their oil every 1000 mile and use synthetic. I use mineral oil with normal service intervals and have no problems entcountered. Lifetime of a camshaft chain is about 30,000 miles.
Forget cylinder wear. A 305 consumes every 12,500 km a 0.01mm of its cylinder. Service limit is 0.1mm.
A bolt for Kawasaki flywheels. The thread is M18x1,5.
A dangerous thing. The automatic camshaftchain tensioner of a 305. When it is dirty or worned out, the bearing looses his grip on the pushrod. I don't know if camshaft timing changes at that moment, but I will not be surprised if so. Replacement of the camshaft chain every 20,000 miles is also a good advice.
Mounting instructions: short spring, ball retainer, circlip, washer, long spring. Tension the long spring with the bolt. After installation, let the pushrod free and refit the bolt.
It's hard to get the engine free from oil. Use liquid gasket in addition to the paper one.
A topcase can be fixed at the lugs of the passenger grip and the blinker. Use some L-shaped iron and some pipe fore keeping distance. The left picture is the framework, showing the lugs. Holds anyway more then 30.000 miles.
Conversion from belt to chain. A chain sprocket fits on a outgoing shaft of a belt machine. Use the nut for locking the sprocket and some washers for aligning the chainwheel. The other way is more difficult. A chain engine has no thread for locking the pulley. You should change the gearshaft or do some welding. On the wheel side both conversions are easy. I have to admit, that I didn't do a conversion, so there could be more problems rising.
Sometimes the O-ring causes leakage. Replacement is not described in the workshop manual.
I have received a tip from Quinn. Fix two screws in the O-ring and pull out the seal. Fit the new ring with a piece of pipe.
The unitrack system is not maintenance free. Mostly you noticed too late the system is fixed with dirt. Lubricating from outside is difficult. Dismantle everthing into pieces. Most dirt comes from wearingdust of the bushing.
Pistons live much longer then the rings. Replacement of the rings after 20,000 miles is advised.
Original frictionplates are not suitable for modern motorcycle oil. They cannot stand the torque. Replace them by new one.
Information about camshaftchain adjustment.Chain

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