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.