305 CSR getting back on the road: timing chain tensioner - Kawasaki Motorcycle Forums
 
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post #1 of 7 (permalink) Old 05-11-2019, 06:39 PM Thread Starter
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305 CSR getting back on the road: timing chain tensioner

Hello all,


I have a 1982 305 CSR which I stopped riding about 5 years ago. I remember I stopped riding it because of a timing chain noise issue, which I determined at the time was a timing chain tensioner. I can remember that these bikes had an issue and there was a modification to fix this issue, but this is all I can remember.


Can someone point me in a direction on how involved this project would be and what I should expect to need to do to get a bike that hasn't been on the road in 5 years. I'm more of an antique car guy, so I have mechanical experience but I have little knowledge of motorcycles.




Thank you,
Brandon
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post #2 of 7 (permalink) Old 05-12-2019, 12:30 PM
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Assuming you don't have the Kawasaki service manual, there's a pdf available on the internet for the KZ305.
The FSM will have specific info for removing, servicing & re-installing the tensioner.
Also, the diagrams at Kawasaki dot com or Partzilla can be handy, as well as EB photos.

I don't know the specifics of your tensioner, but several things to note: read the manual before removing the tensioner or messing with it; don't turn the crankshaft when the tensioner is removed; and do not remove the tensioner mounting bolts only half way.

Mine is different from yours, but I use brake caliper grease to lubricate the tensioner
...

1981 KZ650-CSR. Competition, Sports & Road.
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post #3 of 7 (permalink) Old 05-12-2019, 08:40 PM Thread Starter
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Thanks for the reply. I found some forum posts or articles on changing the auto-tensioner to a manual tensioner several years ago when I first had the issue, but I am no longer able to find these articles. I know one of the big Kawasaki forums has become defunct, so maybe they were on that forum.

Is the auto-tensioner issue a problem throughout the models and engines? I see manual tensioner "kits" available, so it seems this must be a common issue for at least some of the models, but I'm not finding info on how to make the modification.


Brandon
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post #4 of 7 (permalink) Old 05-14-2019, 01:02 AM
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Looking nice
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post #5 of 7 (permalink) Old 05-15-2019, 10:43 AM
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By vetteman61: Is the auto-tensioner issue a problem throughout the models and engines? I see manual tensioner "kits" available, so it seems this must be a common issue for at least some of the models, but I'm not finding info on how to make the modification.

I don't know about the KZ305. Supposedly on some KZ1000s & I'm not certain of the specifics, but under certain throttle conditions, the tensioner pushrod can move forward, over-tightening the cam chain & causing damage. I installed a Krieger/Clem's-Garage manual tensioner on my 1981 KZ650-CSR, but after doing some reading afterwards at the time, I don't think it's necessary. my bike has the cross-wedge type & I don't know what KZ1000 tensioners are supposedly problematic.

Some auto tensioners can be converted to a manual type & the specifics are dependent upon the tensioner. All tensioners have a push rod that pushes against a cam chain guide. My bike & the KZ305 have a Hy-Vo cam chain with rubber slipper cam guides >> the tensioner pushes against the Rr slipper guide. To convert a tensioner, one way is to drill & tap the tensioner body so that an adjusting bolt can be installed thru the body. The new/long adjusting bolt would have a lock nut. You would then adjust the tension by turning in the new adjusting bolt the appropriate amount >> usually lightly until it stops, then back it out x number of turns or x number of flats on the bolt head. or something like that.
....

1981 KZ650-CSR. Competition, Sports & Road.
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post #6 of 7 (permalink) Old 05-18-2019, 11:47 PM Thread Starter
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OK, thank you for the reply. I've been looking all over trying to find a write up with pictures on this but can't find one anywhere.
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post #7 of 7 (permalink) Old Yesterday, 01:16 PM
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Do you mean a how-to for converting the tensioner? Compare yours to the diagrams at Partzilla & EB pics. It looks to me that it would be fairly simple to convert as it's already drilled & threaded thru the end where the adjusting bolt would go.

But I don't know if it's necessary or worth the trouble on a 305. The 1000 has a much more powerful engine & I think most tensioner failure would have occurred at the race track, but don't quote me on that. hee. I thought Ape Racing had a description of the problem, but I couldn't find it.

ps: I may be wrong about your bike having a Hy-Vo cam chain as the drawing shows a roller chain, but it does have the rubber slipper guides.
....

1981 KZ650-CSR. Competition, Sports & Road.
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