Canadian KZ305 LTD

Brrrrat! That's my thoughts anyway. Picked up this little baby on Friday and yesterday spent about 4 hours pulling bits and pieces off and setting how it looks underneath!
Plans are, move rear set to passenger peg position, crop frame just behind rear shocks, new seat, tank, brakes, some clip ons and new paint. I'll post up some pics when I get home.

Don't forget to post some pictures

Finally home after work.

Im almost at a frame, still gotta get the engine off, and them wheels n forks. First timer here so the easy bit is done (in my opinion), removing the rear wheel seems a little more interesting with chain n drum break n all.

For now, my self limited budget is another $750 to get it on the road, bringing total expenditure to $2000CAD

(sorry about the multiple replies, all the phone would let me)

Unfortunately it looks like most of the screws on this cover are stripped, so looks like a trip to a machine shop to get them drilled out and re threaded at $10/$20 a piece.

Got some rust to clean up, hopefully nothing harmful to the structural integrity

Gonna have to give the engine a gooooood scrubbing


Just had to update everyone as to where the project is at now. Only started 1 day ago, put about 4/5 hours work in so far, I don't think its to bad for my first time...

ecannon wrote: Unfortunately it looks like most of the screws on this cover are stripped, so looks like a trip to a machine shop to get them drilled out and re threaded at $10/$20 a piece.

Damn how many screws are there? You might wanna try getting a impact driver, the hammer kind, and save yourself some money. they're pretty cheap (i got mine for $15) and they work great! especially on OEM screws because they are so soft. I have had a couple as bad or worse than the ones in your photos and still gotten them out. just my .02

www.amazon.com/Tool-Aid-SGT14950-Impact-Driver/dp/B000I1X6RU

There's 5 or 6 on that cover alone... Not an exciting prospect. Im gonna be doing some shopping for tools (young first time mechanical worker trying to get my shop together), have a diver set of stripped screw removers, gonna give that a go as some have been nicely rounded off, the others are varying stages of stripped.

So close to ending the beginning! Just the front forks to remove and Mt first project is about to begin! :lol:

Good luck with getting the screws out! I had the same issue with all my covers. them screws were held in good....I got lucky, I could tighten them just enough that they broke loose then unscrewed them, or cracked on the end of a screwdriver to break it sorta loose. beware of hitting on any plastic handle though... they explode.

2 suggestions:

You need to order a can of Kroil (see: Kroil 1/2 pint (8 oz.) can - $8.50 ea. in link below). You soak stuck screws with this stuff for 2 or 3 days before trying to remove them and they will be 1000 times easier to remove - no kidding.

www.kanolabs.com

You need to get some Phillips screwdriver tips (#3 for the big screws, #2 for smaller screws) and modify them as shown in the link below. The screws on Kawasakis that look like Phillips are not Phillips; they are JIS - see link and the links it includes for explanation on how to make proper screwdriver bits.

kzrider.com/forum/13-bike-related/519588-tips#519601

Meanwhile in Canada...
www.amazon.ca/SG-Tool-Aid-SGT14950-Impac...d=1337621319&sr=1-89

After such a good start to the project, it seems to be slowing down with my lack of tools and knowledge. The front end is still attached so that should be coming off in the next day or two, then, until I have spare time to make a trip state side to pick up some goodies, it seems I`ll be slow going for a while.

On the states shopping list currently;
- hand impact driver
- kroil
- rustoleum
- spray gun
- any misc parts that I figure I might need between now and then

Sure hope it all fits in my saddle bags...