Target Audience:
Do-it-yourself owners and experienced mechanics.
Value Proposition:
Inexpensive way to keep the vehicle working properly and perform repairs.
Advantage Over Competitors:
Complete official factory data, detailed step-by-step procedures with extensive illustrations, instant digital delivery without shipping delays.
Searchability:
PDF format allows for easy searching of keywords and topics.
Navigation:
Numbered table of contents for quick information retrieval.
Engine Mechanical:
Full disassembly and reassembly, cylinder head, pistons, crankshaft, lubrication system, cooling system (if applicable, though typically air-cooled for this era/model).
Fuel System:
Carburetor (twin Mikuni VM series likely), fuel pump (if equipped), fuel tank, fuel lines.
Ignition System:
CDI ignition, ignition timing, spark plugs, coils.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox internal inspection and repair, final drive (chain).
Electrical System:
Wiring diagrams, charging system (alternator/stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, switches.
Chassis Suspension:
Front fork overhaul and adjustment, rear shock absorber inspection and replacement, swingarm, steering head bearings.
Braking System:
Front disc brake (caliper, master cylinder, fluid), rear drum brake (shoe inspection and replacement).
Bodywork Trim:
Panel removal and installation, seat, fenders, fuel tank, side covers.
Maintenance:
Oil changes, filter replacement, chain lubrication and adjustment, brake adjustment, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common issues, electrical system troubleshooting with detailed wiring diagrams.
Repair:
Step-by-step instructions for complete disassembly, component repair, and reassembly of all major systems.
Technical Adjustments:
Carburetor synchronization and tuning, ignition timing, valve clearance adjustment (if applicable).
Depth:
Comprehensive factory-level detail, suitable for both DIY enthusiasts and professional mechanics.
Illustration Detail:
Hundreds of photos and illustrations, detailed drawings, enlarged inset diagrams for critical components.
Instruction Format:
Numbered instructions, detailed substeps, notes, cautions, and warnings for critical information.
Engine Displacement:
305 cc
Engine Configuration:
305cc, 360-degree Inline Two-Cylinder, Four-Stroke
Bore X Stroke:
53.0 x 56.0 mm (estimated based on similar models)
Compression Ratio:
9.5:1 (estimated)
Cooling Method:
Air-cooled
Valve Actuation:
DOHC (Dual Overhead Camshafts) - likely SOHC (Single Overhead Camshafts) based on model heritage, manual will confirm.
Horsepower:
Approx. 29-32 hp @ 8,500 rpm (estimated)
Torque:
Approx. 18-20 lb-ft @ 7,000 rpm (estimated)
Carburetion:
Twin Mikuni VM30SS carburetors (typical for this model).
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended, check manual for specific grade).
Oil Type:
SAE 10W-40 motorcycle specific engine oil, API SG or higher (check manual for exact specification).
Oil Capacity:
Approx. 2.5-2.8 liters with filter change (check manual for exact capacity).
Ignition System Type:
Transistorized Ignition (CDI)
Spark Plug Type:
NGK DR8ES-L or equivalent (check manual for exact part number).
Spark Plug Gap:
0.7 - 0.8 mm (0.028 - 0.031 in) (check manual for exact specification).
Overall Length:
Approx. 2130 mm (83.9 in) (estimated for 1980 model, variations may exist)
Overall Width:
Approx. 760 mm (30.0 in) (estimated for 1980 model)
Overall Height:
Approx. 1165 mm (45.9 in) (estimated for 1980 model)
Dry Weight:
Approx. 159 kg (350 lbs) (estimated for 1980 model)
Wet Weight:
Approx. 170 kg (375 lbs) (estimated, includes fluids)
Front Tire Size:
3.00-18 4PR (typical, check manual for specific fitment)
Rear Tire Size:
100/90-18 56P (typical, check manual for specific fitment)
Front Wheel Type:
Spoked 18-inch
Rear Wheel Type:
Spoked 18-inch
Safety Ratings:
N/A (Motorcycle safety standards vary by region and era; manual will detail system design).
Braking System:
Front hydraulic disc brake, rear mechanical drum brake. Manual details servicing for optimal performance.
Lighting System:
Headlight, taillight, brake light, turn signals. Manual covers bulb replacement and wiring.
Infotainment System:
N/A (Motorcycle of this era relies on analog instrumentation).
Driver Assistance Features:
N/A
Connectivity Features:
N/A
Instrument Panel:
Analog speedometer, tachometer, fuel gauge (if equipped), indicator lights (high beam, turn signal, neutral).
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first (typical recommendation, consult manual for precise interval).
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain (typical recommendation).
Spark Plug Replacement:
Every 10,000 km (6,000 miles) (typical recommendation).
Valve Clearance Check:
Every 8,000 km (5,000 miles) (if applicable, consult manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific requirement).
Coolant Type:
N/A (Air-cooled engine).
Common Wear Items:
Carburetor diaphragms (if vacuum slide), fork seals, clutch plates, chain and sprockets, wheel bearings.
Electrical Gremlins:
Corrosion in connectors, aging rectifier/regulator, intermittent stator output (common for bikes of this age). Manual's wiring diagrams are crucial.
Kawasaki Legacy:
Kawasaki Heavy Industries' Motorcycle & Engine division has a long history of innovation in performance and reliability across various engine types and displacement classes.
Kz Lineage:
The KZ series represented Kawasaki's successful entry into the multi-cylinder motorcycle market, evolving through various displacements and configurations in the late 1970s and early 1980s. The KZ305 was positioned as an accessible, sporty middleweight.
Manufacturing Location:
Likely Japan, though specific plant details may not be in this manual.
