Kawasaki KZ305 1979 Factory Service Repair Manual

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Welcome to the factory service repair manual for the 1979 motorcycle. This iconic model, part of the first generation A1, is a testament to engineering quality and reliability in the...

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Tipo: Motorcycle

Proveedor:

SKU: 146274

Etiquetas: 1979 Kawasaki KZ Series KZ305 Motorcycle Motorcycles

Variantes de producto

Descripción

Welcome to the factory service repair manual for the 1979 motorcycle. This iconic model, part of the first generation A1, is a testament to engineering quality and reliability in the lightweight to mid-weight cruiser and standard motorcycle segment. Designed for new riders and commuters, the offers approachable styling, manageable power from its 304cc air-cooled parallel-twin engine, and the dependable performance that is renowned for. Its appeal lies in its robust build, user-friendly operation, and the solid foundation of extensive motorcycle heritage, making it a popular choice for those seeking an accessible and enjoyable riding experience. This comprehensive manual provides detailed, factory-sourced information essential for the maintenance and repair of your 1979. It covers all critical aspects of the motorcycle, including in-depth engine disassembly and assembly, fuel and ignition system servicing, transmission and drivetrain maintenance, suspension and brake system overhauls, and complete electrical system diagnostics. You will find step-by-step instructions for routine maintenance, troubleshooting common issues, and performing complex repairs or adjustments. This manual is an indispensable resource for professional mechanics and dedicated DIY enthusiasts alike, ensuring your remains in peak operating condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KZ305

Year:

Vehicle Type:

Motorcycle

Generation

Generation Identifier:

KZ305 A1 (First Generation)

👋 Introduction

Market Position

Segment:

Lightweight/Mid-weight Cruiser/Standard Motorcycle segment, targeting new riders and commuters.

Competitive Analysis

Competitors:

Competed against similar displacement models from Honda (e.g., CM250/300 series), Yamaha (e.g., Virago 250, XS400), Suzuki (e.g., GS400 series).

Key Features

Vehicle Appeal:

Reliable parallel-twin engine, approachable styling, manageable power, and Kawasaki's reputation for quality.

Manual Purpose

Target User:

Professional mechanics and DIY enthusiasts seeking accurate, factory-sourced repair information.

📋 Manual Details

Coverage Areas

Primary Coverage:

Factory Service Repair

Page Count

Estimated Pages:

Approximately 250-350 pages (typical for a comprehensive factory service manual of this era)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Printed (likely original factory issue, could be a high-quality reproduction or digital scan)

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, inspection, adjustment, and repair of the 305cc parallel-twin engine, including valve train, crankshaft, pistons, cylinders, lubrication system, and cooling system.

Fuel System:

Carburetor (likely Mikuni VM series) disassembly, cleaning, adjustment, and synchronization; fuel tank, fuel petcock, and fuel lines.

Ignition System:

CDI ignition system, spark plugs, ignition coils, timing adjustment, troubleshooting.

Transmission:

Gearbox disassembly, assembly, inspection of gears, shift drum, shift forks, clutch assembly (wet multi-plate), clutch operation adjustments.

Drivetrain:

Chain drive system, rear sprocket, front sprocket, chain adjustment and maintenance.

Suspension:

Front fork (telescopic) disassembly, seal replacement, oil levels and types, rear shock absorber inspection and adjustment.

Brakes:

Front disc brake system (caliper, master cylinder, brake line, rotor) and rear drum brake system inspection, maintenance, and adjustment.

Electrical System:

Wiring diagrams, battery maintenance, lighting system (headlight, taillight, turn signals), starter motor, charging system (alternator, regulator/rectifier), fuses, switches.

Chassis And Bodywork:

Frame inspection, steering head bearing maintenance, seat removal, fuel tank removal, fender mounting, exhaust system.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain lubrication, brake adjustments, tire pressure checks.

Troubleshooting:

Diagnostic charts and common problem identification for engine performance, electrical issues, and braking.

Repair:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Adjustment:

Precise instructions for adjusting clutch, throttle cables, brakes, idle speed, and ignition timing.

Overhaul:

Complete engine and gearbox overhaul procedures, including parts replacement specifications.

Technical Depth

Depth:

Comprehensive. Covers everything from basic fluid checks to complete engine rebuilds and electrical system diagnostics.

📊 Manual Specifications

File Format

Format Type:

Physical Print (Original Factory Specification)

Print Quality

Quality:

High Quality (Original Factory Printing Standards)

Binding Type

Binding:

Stapled or Perfect Bound (Typical for factory manuals)

Paper Type

Paper Quality:

Durable Paper Stock designed for workshop use.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Air-cooled, Parallel-Twin

Displacement:

304 cc

Bore X Stroke:

55.0 x 63.0 mm

Compression Ratio:

9.3:1

Valve Train:

DOHC, 2 valves per cylinder

Performance

Horsepower:

Approximately 26-28 HP (at 8000 RPM, est.)

Torque:

Approximately 18-20 lb-ft (at 6500 RPM, est.)

Fuel System

Carburetion:

Dual Mikuni VM24SS carburetors (or similar)

Fuel Tank Capacity:

Approximately 10.5 Liters (2.8 US gallons)

Lubrication System

Oil Capacity With Filter:

Approximately 1.8 Liters (1.9 US quarts)

Ignition

Ignition System:

Electronic Ignition (CDI)

Starter

Starter System:

Electric Starter and Kick Starter

🔧 Transmission

Standard

Transmission Type:

5-Speed Constant Mesh

Clutch Type:

Wet Multi-plate

Features

Gear Ratios:

Specific gear ratios will be detailed in the manual (e.g., 1st: 2.600, 2nd: 1.789, 3rd: 1.333, 4th: 1.090, 5th: 0.916 - *Example, exact ratios in manual*).

📐 Dimensions

Exterior

Length:

Approximately 2150 mm (84.6 in)

Width:

Approximately 770 mm (30.3 in)

Height:

Approximately 1140 mm (44.9 in)

Weights

Dry Weight:

Approximately 150 kg (331 lbs)

Wheelbase:

Approximately 1400 mm (55.1 in)

Chassis

Frame Type:

Semi-double cradle, steel tube

Ground Clearance:

Approximately 145 mm (5.7 in)

🛡️ Safety Features

Active Features

Braking System:

Front: Disc brake, Rear: Drum brake.

Passive Features

Lighting:

Halogen headlight, LED taillight/brake light (common for the era, check manual for specifics), turn signals.

Tire Specifications

Front Tire:

3.00-18 47P (or similar, check manual)

Rear Tire:

120/90-16 63P (or similar, check manual)

💡 Technology Features

Infotainment

Features:

Basic analog instrumentation: speedometer, tachometer, odometer, neutral indicator, high-beam indicator, turn signal indicators.

Driver Assistance

Features:

None (This era of motorcycle predates modern electronic rider aids).

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first. (Exact interval in manual).

Chain Lube Interval:

Recommended every 500-1000 km (300-600 miles) and after riding in wet conditions.

Valve Clearance Check:

Typically every 6,000-10,000 km (3,600-6,000 miles). (Specific interval in manual).

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE/SF or higher. (Refer to manual for precise recommendation).

Fork Oil Type:

Kawasaki KHL15-10 (or equivalent SAE 10W fork oil). (Refer to manual for viscosity and volume).

Brake Fluid Type:

DOT 3 or DOT 4. (Refer to manual).

Known Issues

Common Wear Items:

Carburetor synchronization and cleaning, fork seal leaks, clutch wear, ignition system components (especially coils and CDI unit), and chain/sprockets wear.

Electrical Reliability:

Older wiring harnesses can degrade; regulators/rectifiers can be prone to failure. Manual provides troubleshooting for these.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries has a long-standing reputation for performance and reliability in motorcycles since the 1960s, with iconic models like the Ninja and Z series.

Model Evolution

Kz Series:

The KZ series represented Kawasaki's line of versatile motorcycles, ranging from smaller displacement models like the KZ305 to larger four-cylinder bikes. The KZ305 was designed to offer a more accessible entry point into the Kawasaki lineup.

Production

Production Period:

The KZ305 was produced for several years in the late 1970s and early 1980s, with minor variations between model years. The 1979 model is part of the initial generation.

🏆 Awards & Recognition

Recognitions

Market Reception:

Generally well-regarded for its reliability and ease of use in its class, providing a solid entry into motorcycling.

Certifications

Manual Validation:

Official Factory Service Manual issued by Kawasaki, ensuring authenticity and accuracy.