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replacing cylinders on 305 19 Mar 2023 07:54 #881771

  • 82KZ305Belt
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2 years ago I rebuilt the top end of my 305 but since oversized cylinders are unobtainium I couldn't do a rebore. The right cylinder was scored so I replaced that piston with a new one, but honing did not quite smooth out the bore so the rebuild was not entirely successful. It ran but smoked and blew oil on that side and lacked power.  I rode it up and down my street 15 total miles that summer, never getting above 45, and it hasn't been started since.

So after years of searching I finally found used cylinders that look good, but I won't know for sure until they arrive and get them measured. Assuming they are good to use with standard 61 mm pistons, do I need to do anything other than install it with new gaskets? Can I go with the present rings, which only have 15 miles on them?

 

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replacing cylinders on 305 19 Mar 2023 09:52 #881776

  • Wookie58
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Are these the rings that where fitted when it melted a piston ? If not I would think you will be ok but if they are, for the price I would replace (especially given the problems finding barrels)
1982 KZ1000 Ltd

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replacing cylinders on 305 19 Mar 2023 10:44 #881780

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Are these the rings that where fitted when it melted a piston ? If not I would think you will be ok but if they are, for the price I would replace (especially given the problems finding barrels)

 

No that was a more recent thread from a different poster. My right skirt was scored along with the right cylinder, but I had the bores honed and replaced the bad right piston (kept the left one) and installed new rings on it. So all of the rings, and the right side piston, only have 15 miles on them. The left piston looked fine so I kept it and it has new rings with only 15 miles.

 

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replacing cylinders on 305 19 Mar 2023 13:47 #881791

  • Nebr_Rex
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You should be fine as long as the pistons and rings have no sharp edges or burrs.


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2002 ZRX1200R
81 GPz1100
79 KZ1000st daily ride
79 KZ1000mk2 prodject
78 KZ650sr
78 KZ650b
81 KZ750e
80 KZ750ltd
77 KZ400/440 cafe project
76 KZ400/440 Fuel Injected

www.dotheton.com/forum/index.php?topic=39120.0


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replacing cylinders on 305 23 Mar 2023 15:53 #881905

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My used cylinders arrived and they look great. I still need to get them measured and looked at by a pro but other than not seeing cross hatching I see no wear at all and they certainly haven't been overbored. Should I get them honed? I suppose with the rings being new-to-the-cylinders that I should, huh? Hate to take any metal off but guessing I need that hone

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replacing cylinders on 305 24 Mar 2023 05:12 #881914

  • hardrockminer
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Yes, they should be honed.
I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.
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