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Thanks guys. It is a great little bike. When the guy delivered it, I sat on it and it was a big flash back. When I was 15 in a small town school, all my friends had 125 enduros. Man I could really smoke them guys I think just about every cheerleader got a ride on it too. I sure wish I could have found my original bike. I'm a sucker for nostalgia.

Thanks for the great documentation. I picked up a few nice tips here. Ypur mother did a fantastic job on the seat.
Wayne

Nice work! I'm thinking of chopping a few inches from my Gpz750 screen. How did you cut your screen?

Later, Doug

StreetfighterKz wrote: Nice work! I'm thinking of chopping a few inches from my Gpz750 screen. How did you cut your screen?

Later, Doug

Doug, I used an electric 4 inch grinder with a very thin cutting disk. Wear gloves because it slings hot plastic. I then used 180 grit on a sanding block to smooth the edge

Well, we got warm weather coming so it's time to get this bike torn down and start spraying color. I just got it tagged and insured. Tonight I used a #6 stainless washer under the head of each needle and drilled the pilot jet a tad bigger. This is supposed to take away the leanness and hesitation. Gonna try it out tomorrow. If its running well, it will be a bare frame by sunday. I have bought every part needed over the winter including the paint. It will be nice to have a small bike to do my errands on.

I went and bought an index set of bits for $3 at my local tool place. I got two sets of metric and one set of standard so about $10 total. The 305's have a stock lean condition that causes hesitation off idle. I drilled the pilot jets to 40. Stock is 35. I also put a #6 washer under each needle on the slides. It starts better especially cold and runs amazing. No more hesitation. I was told this recipe was in a 1983 Cycle World magazine. I ordered the mag but it has not come in yet. Heck, I'm going to go back out and ride it some more.

It's stripped apart. Now its time for all the new paint and parts. There's a few of us taking our little bikes out for a 120 mile ride in 3 weeks so its balls to the wall time.

Sweet thread! I am definitely going to be following this one.. it's good inspiration as I kick off my build. I'm off to pick up an s10 headlight!