81 KZ305 project

[RoseyVelt]

Dropped off the tank to be cleaned and sealed. Does $75 sound crazy? I thought so...
Scouring the web for some carb boots. I would like to get some made from metal and just fit an o-ring in a groove. Anyone out there with some skilz, pm me. I can send you the original carb boot. Just need the flange really.

While I'm waiting for boots, tank, and throttle cables, I'm contemplating opening up the the side and having a look at the clutch. The clutch lever doesnt move the cable at all. Also I dont think it is shifting past first. I can put it in neutral but going down (1st) then a full shift up(2nd) feels "mushy"...

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[RoseyVelt]

I was a few minutes away from driving to harbor freight and getting a grinder to cut the bolts off the left cover when.... I finally learned how to use a f&$@#!+ impact driver.

Some nasty bolts I'm replacing tomorrow.

Removed the clutch cover only to find the nastiest shit

Small victories... Leaving it as is until tomorrow.

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[RoseyVelt]

Woot! Grandparents came in to buy stuff for their businesses in dallas and brought me the xs11!!!! More projects=more betterer right?

Also my grandfather is taking the original carb boots and welding some pipe to fit the new carbs. Throttle is on the way as well as new points and points cover! Got it for a steal on ebay.

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[RoseyVelt]

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[DesmoBro]

Sweet dude i have 3 of them xs11s right now none run just like my 305 ....good stuff....

 

[RoseyVelt]

Nice! I've been lurking around xs11 forums as well. Rumor has it there's a guy who shaved close to 200# off his xs11 that's where I'd like to go with mine. The ol girl is HUGE! I've subscribed to yours. Any luck with front-end swap?


New points and points cover came in! The OG looked pretty ratty and the cover came with one anyway so I thought why not.

I took a look at the timing part of the manual and I think it requires something to measure the distance between the contact points but I have no such thing. Also, I can't seen to find the "1" & "2" marks on this bit...

Sweet dude i have 3 of them xs11s right now none run just like my 305 ....good stuff....

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[DesmoBro]

No luck finding anything worthy of a swap ....trying to keep it as bank account friendly as possible....so far it looks like ill be rebuilding the front and rear calipers....which really makes me itch for that swap....cant win...

 

[dilbone]

I'm afraid I'm no help for you on this bike, but I'm enjoying the journey you've posted. Both of my project bikes were recent runners so haven't had near issues you've had already just in getting this one in running condition. Sorting out the replacement of the TCI ignition on my XS650 was as bad as things got for me.

Looking forward to seeing this sucker fire up. Nice work so far.

 

[RoseyVelt]

I'm afraid I'm no help for you on this bike, but I'm enjoying the journey you've posted. Both of my project bikes were recent runners so haven't had near issues you've had already just in getting this one in running condition. Sorting out the replacement of the TCI ignition on my XS650 was as bad as things got for me.

Looking forward to seeing this sucker fire up. Nice work so far.

Thanks a ton and no worries. Im just trying to concentrate on small wins to keep me going lol just hoping I don't hit some kind of wall. I'm going to need some input and expertise when I go to chop this thang for sure though.

Got the tank back! Sickens me to spend so much on something I may not even use lol oh well.

Any all purpose parts cleaner you guys can suggest? I was going to pick up a bucket of brake cleaner. Just want something cheap to use on parts while I wait on other parts to ship.

I've been using an old tooth brush, pine sol, and soapy water.. Not working well

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[DesmoBro]

I bought the manual for the 305 so if you need any measurements etc i can take a picture

 

[RoseyVelt]

I bought the manual for the 305 so if you need any measurements etc i can take a picture

Damnnnnnnnnn. I could really use that wiring harness. The scanned one I have is impossible to read

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[dilbone]

Kerosene and a tooth brush did wonders for me. It'll cut grease without some of the harsher chemicals IMO

 

[DesmoBro]

Super tough to get a good picture let me know if u need a close up

 

[RoseyVelt]

Super tough to get a good picture let me know if u need a close up

Thanks a ton desmo. I'll be asking for a closer shot once I start rewiring for now They're saved on my phone.

Clutch cable from ebay and 2 into 1 throttle from dcc came in today! Spent about an hour trying to replace the clutch cable only to find out it's shorter than stock. It was from an 82

Not sure how much shorter. I was too mad at myself to take it back apart. How the clutch works completely boggles my mind. Going to Google that till I fall asleep. In the meantime my grandpa is welding on the flange mounts for the carbs! Maybe next weekend

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[DesmoBro]

Run shorter handle bars if you can to give you a couple inches

 

[RoseyVelt]

Run shorter handle bars if you can to give you a couple inches

Simple answer. I like it. I was planning on running straight bars but for now maybe I can turn my stock ones down. When I get frustrated I get tunnel vision


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[DesmoBro]

There is a used moto parts place near me they sell bars for $5 and even a pair of new dirtbike bars can be low as $15 in a new shop ....i also get stuff from yard sales and flea markets on the weekends

 

[RoseyVelt]

There is a used moto parts place near me they sell bars for $5 and even a pair of new dirtbike bars can be low as $15 in a new shop ....i also get stuff from yard sales and flea markets on the weekends

Noice. I'll measure the bar tomorrow. Do you have a handlebar stash lying around? but seriously if you've got some, pm me some pics. There's a used shop in ft worth but that's a jaunt for me.

Also, grand pops got the carb boots welded. Picking them up next weekend. Bolts come in Monday. Got the clutch cable to work ii think. Went to put it all back together and Broke shifter and sheared the bolt...

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[DesmoBro]

Damn that sucks i have some bars but id have to dig em out also have a parts KZ305 motor similar but different lots of the same parts tho

 

[RoseyVelt]

Went to fastenal for the bolts but they ordered Phillips instead of allen :/ ordered a new shifter for $20 and decided to work on something else! Going through the front brakes!

break reservoir

Hopefully buy myself some time inside

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