I need a seriously good source of NOS Kawasaki bits - or even scrap parts!

simple is good that is why i suggested an acumulator they only require one oil hose less bother than hooking up an aftermarket oil cooler
a metal gear may not work well it may just wear out the drive gear it mates to
i think you are on a good road expanding the suction nozzle

'blueprinting " the pump is a good road also
basically free ,it is just to make sure all running clearances are as low as possible to maximize the output to modify if needed to make it same efficiency and output as the designers blueprints intended it to be
is the 305 a 180 or 360 crank
 
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