KZ305 Build

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Mikerodrig27

New Member
Hey guys. I've been lurking around here on the forums for a couple of months. I've been needing something to wrench on for a while so I posted an ad up in my area looking for a motorcycle project and I find one. Someone contacted me letting me know they had a 1987 KZ305 LTD sitting in their garage collecting dust rust and everything else you'd find on something old.

IMG_3384.jpg


It was last registered in 1996 and I'm guessing it was put away wet. It has been sitting for so long that my county has booted the registration information out of their system and doesn't even know it exists anymore which is good for me because now I don't have to pay back taxes! The price was right as the previous owner needed the space for house projects and he was getting ready to send it to the junk yard. He was a really nice guy and even included a service manual and a couple odds and ends.

I'm going to do sort of a cafe racer/brat type of bike. I think it is going to be cool. I have a color scheme and stance in mind so hopefully I can make it happen.

So to start off with, I need to get it running. so far it definitely needs a set of carburetor holders (Part #16065-1069) which I've sourced on PartsZilla but they have to special order them. I've pulled the carburetors apart and they are surprisingly clean other than the jets being gummed up. I have already cleaned them and set them aside. I'm going to check to see if the starter motor still works, turn it over and check for spark.

Updates to come.
 
Thanks! I have the bike completely disassembled. The only thing left on the frame are the forks and swingarm. I'm going to start going through the parts as far as rust removal etc. I'm going to be zinc plating my own parts if I can manage to pull it off. I'm going to be following this thread: http://www.triumphrat.net/classic-vintage-and-veteran/160243-zinc-plating-at-home.html

A few things I've accomplished so far:

-Turn motor over with starter using a car battery

-Set up rust a electrolytic rust removal tank

-Bought a hand impact driver kit which changed my life forever! I tried to get some bolts out with other methods including a my 18v Hitachi impact gun and decided to swing by O'reilly Auto and pick this up. A couple hits of the hammer and the bolts are out. Napa, advanced auto, discount and all the other auto places should have an equivalent
http://www.oreillyauto.com/site/c/detail/PFM0/W2500P.oap?ck=Search_impact+driver_-1_-1&keyword=impact+driver

-Bought a digital caliper it's very accurate when measured against my starrett micrometer. It doesn't move smoothly but it isn't $300 either. It's been awesome for looking for wear on different parts.
http://www.lowes.com/pd_293883-16878-53247_0__?productId=1242475&Ntt=caliper&pl=1&currentURL=%3FNtt%3Dcaliper&facetInfo=

-Bought Pure zinc bullions from Ebay seller XretiredX:
http://www.ebay.com/itm/231388907199?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

-Torn bike completely apart aside from the forks and swingarm. I even took the old tires off of the rims today

This is my short list of things to do in the near future:

-Source out a soda blaster to clean up the engine
-Get some air craft paint stripper for the frame and other painted parts that need recoating
-start zinc coating bolts and other parts
-Order the carburetor boots (I have to call to order them)
http://www.partzilla.com/parts/detail/kawasaki/KP-16065-1069.html

This picture is of the bike at the intermediate stage of teardown. I'll more pics of it soon.

IMG_3448_Large.jpg
 
I've often found a wire cup wheel on an angle grinder works better than chemical strippers. Nice progress so far.
 
Thanks Rusty, your bike came out great. I hope I can get mine to look as good.

Tifun, I may resort to those as I already have a few quick strip disks along with cut off wheels and grinding disks. The one thing I like about paint stripper is that you don't end up putting scratches in the frame that may show through the paint unless you prep them out.
 
Mikerodrig27 said:
Thanks Rusty, your bike came out great. I hope I can get mine to look as good.

Tifun, I may resort to those as I already have a few quick strip disks along with cut off wheels and grinding disks. The one thing I like about paint stripper is that you don't end up putting scratches in the frame that may show through the paint unless you prep them out.
Click to expand...

A wire cup/wheel shouldn't leave marks. A flapper disc and grind disc will for sure.

Keith
 
Hmm, I'll take your advice and shoot over to Lowes and grab one. The more I think about it the more I don't feel like dealing with chemical strippers. Now I just need to make sure I don't get a wire stuck in my eye... :eek:
 
Have you considered getting you frame sand blasted? I found it very cost effective.

Sent from my HTC_0P6B using Tapatalk
 
There is a place around here that does it. I was thinking of calling them and asking how much they charge. I may do that within the next couple of days. I wanted to have the motor soda blasted but I'm not sure if they offer soda blasting.

http://www.powdercoatinghawaii.com/
 
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