Cam Chain Tensioner

Hello all,

I parked my 1982 KZ305 CSR about 5 years ago due to a cam chain tensioner issue. I'm ready to try to get it running again. I haven't been able to find out much information about this online. I know the original tensioner was automatic. I'd like to install a manual tensioner but I cannot find anyone that makes one or knows how to do this for this engine. Local shops are of no help, even the Kawasaki dealer. I tried to cross reference the gaskets, but they use an O-ring instead of a gasket. I'm not sure what to do now, but I really would like to be able to ride the bike again. I hope someone here can offer some information so I can get it back on the road.

Thanks,

What's wrong with the tensioner you have. I'm not specifically familiar with the one on the 400 but the automatic tensioner is generally serviceable on most KZ's unless you are racing all the time.

The Kawasaki dealer should have the o-ring & Z1Enterprises.com may have it as well. Alternatively, a metric nitrile o-ring kit probably has 1 or 2 sizes that are close enough, if not the same. If you go with the original tensioner, I would replace the circlip >> it's also available from the Kaw dealer & probably a standard metric size available anywhere. I use Permatex ultra brake caliper grease to lubricate the tensioner, which I think is about the same as molybdenum disulfide suggested in the manual.

If you want a manual tensioner, maybe try contacting Kieger Tensioners aka Clem's Garage. They make tensioners for the KZ650/750 & other Kawasaki models. Edit: Or just do it yourself. I looked at the diagram drawing more carefully & it looks like it could be done fairly easily.
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The engine began making a noise which I determined was the cam chain. Looking into it, I found out the cam chain tensioners were automatic on these models. From what I can tell it seems as though the springs wear out inside the tensioner, so I'm not sure how it would be serviceable without finding a new spring. I would prefer to just use a manual tensioner so I don't have to worry about it going bad again.
I was only looking for the gasket because i thought it would be a larger, paper style gasket and would allow me to match up other tensioners to see if they would be compatible. I'm not sure what you mean by a circlip? I'll contact Clem's Garage. I've contact APE and they didn't even know there was a 305, haha.

The circlip is number 480 in the diagram.

www.partzilla.com/catalog/kawasaki/motor...haft-chain-tensioner

Also, Partzilla notes that the oring is also used on the 250 Ninja tensioner and that the shorter of the two springs for the 305 is still available.

Although the 305 and 250 have different part numbers for the longer spring, I wonder if it would be with buying a new 250 spring to compare to your old spring.?

From the diagram drawing the KZ305 tensioner looks like it could be converted to a manual tensioner very easily. It seems to me that you could replace the tensioner bolt #110 with a longer bolt to act as an adjusting bolt plus add a locknut or 2 (and keeping everything else in place except maybe not the springs?). Then adjust the new adjusting bolt the same way as other manual tensioners & lock the new adjusting bolt in place after doing the adjustment by tightening the lock nuts. I would probably get a hardened bolt, but probably not necessary.

M6x14mm bolt 112B0614 >> EB #173145426066

Tensioner push-rod >> EB #371949415723

Rr cam chain slipper guide >> EB #132328024045
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Take your tensioner out and send it to APE. Probably have a match.

Punch up the numbers of the springs and o ring on ebay..... I picked up a spring for mine (650) and it was quite a bit stronger feeling over the old one. Like Jay said he could maybe set you up too but I was worried I'd set it too tight and since the automatic always worked well I left it alone.