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1981 Kawasaki GPz550: Restoration

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    Oh man Steve, you're killing me! That's the nicest looking parts I've seen in a while! Damn shame to tear that thing apart! A man's gotta do what a man's gotta do though.
    Ed

    To measure is to know.

    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

    KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

    Comment


      Originally posted by Nessism View Post
      Oh man Steve, you're killing me! That's the nicest looking parts I've seen in a while! Damn shame to tear that thing apart! A man's gotta do what a man's gotta do though.
      +1 To nice for one of my projects

      Comment


        Some must die so that others may live.......

        As a 17 year old I used to drool over a neighbours Gpz 550, it's been great reading your thread, even though it has been painful at times. You will get there, keep us all informed when you can.

        A strong cup of tea works wonders over here at these moments.

        Cheers,
        Greg
        Suzuki GS1000 1978
        Honda CB400F 1976

        Keep smiling it makes the management nervous.

        Comment


          Been busy like everyone else but making good progress. The KZ550 donor which I got for $400 looks much better on the outside, Gas tank is totally rusted inside, carbs the same, chain seized solid. PO lived on a road base country road. A field mouse made a nest in the airbox, ate or chewed up the air filter and used the rear frame tubes for a crap pile. The fork are soaked in oil but the fork tubes are good



          Another smelly view


          Last week before getting serious about dismantling, I checked the compression by running cables from the Tacoma. The girl still has life in her. 150 psi across cylinder 1-4 with oil squirted into cylinder #2. Check out the plugs above.



          I had fun dismantling the cylinder head because pretty sure this motor has never been apart. The I & E valve lash were still set to the loose side and every cam bearing bolt snapped loose. Here is what the lash & shim sizes look like. I suspect Kawasaki set the valve lash right in the middle of the range of 2.00 to 3.00mm. I am tempted to use this head considering its condition. Lap the valves, change the valve springs and then replace the valve stem seals it should be tight.
          KZ550 Valve Clearance
          Date: 4/16/17 Cyl 1 Cyl 2 Cyl 3 Cyl 4
          In .004-.008 0.008 0.006 0.008 0.008
          Shim 2.60 2.60 2.50 2.50
          Ex .006-.01 0.007 0.008 0.007 0.007
          Shim 2.45 2.60 2.55 2.60
          Compression (Psi) 150 120* 145 150
          * 150 with oil
          1979 GS1000E (44 Yrs), 1981 GPz550
          Departed: 1970 Yamaha R5A, 1971 R5B, 1975 Honda XL250, 1983 Suzuki PE175, 1983 CB1100F, 1983 BMW R100RS, 1992 ST1100

          Comment


            I cut the chain off yesterday with a bolt cutter which caused problems today removing the clutch hub nut today. I pm'd Gearhead13 and he reminded me to use the rear brake to remove the clutch hub nut (Doh!). I used a crow bar wedged between the foot peg bolt to hold the inner clutch hub stationary. The Harbor Freight impact worked as advertised which brings me to the donor. Dr. Steve the donor has been anesthetized . . . I want your crank

            Last edited by srsupertrap; 04-23-2017, 09:41 PM.
            1979 GS1000E (44 Yrs), 1981 GPz550
            Departed: 1970 Yamaha R5A, 1971 R5B, 1975 Honda XL250, 1983 Suzuki PE175, 1983 CB1100F, 1983 BMW R100RS, 1992 ST1100

            Comment


              I was disappointed with the 1st picture, didn't look like a donor bike. Impressed with next pictures, does look like a donor. Hope things go a lot better this time.
              1983 GS1100E, 1983 CB1100F, 1991 GSX1100G, 1996 Kaw. ZL600 Eliminator, 1999 Bandit 1200S, 2005 Bandit 1200S, 2000 Kaw. ZRX 1100

              Comment


                Coming right along Steve. Good work.

                Using the head would be very tempting. I'd look at it closely to see if the seats and valves are truly as good as the compression numbers suggest. On my 750 head the seats were uneven for width, presumably from the factory, so that had to be cleaned up even though the engine was low mileage. Don't assume anything...
                Ed

                To measure is to know.

                Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                Comment


                  Steve,

                  Hope you're swapping out the primary chain and starter clutch also, while you have the two motors apart
                  1978 GS 1000 (since new)
                  1979 GS 1000 (The Fridge, superbike replica project)
                  1978 GS 1000 (parts)
                  1981 GS 850 (anyone want a project?)
                  1981 GPZ 550 (backroad screamer)
                  1970 450 Mk IIID (THUMP!)
                  2007 DRz 400S
                  1999 ATK 490ES
                  1994 DR 350SES

                  Comment


                    Originally posted by Cipher View Post
                    Im surprised that did not bust your crankcases or do some other sort of horrible damage.
                    Did you dind all the bits in the oilpan? Are these parts still available?
                    Good question, here is the extent of the damage to the upper case. I will examine it closer but hoping for the best & plan to increase the radius. I want to keep this crankcase since its a survivor (S/N 000030 or maybe its 25). I did fish out most of the shattered cylinder liner parts and will be splitting the crankcase halves this weekend.

                    PS: Free boat anchor inside, you pay shipping & handling

                    Last edited by srsupertrap; 05-02-2017, 10:46 PM.
                    1979 GS1000E (44 Yrs), 1981 GPz550
                    Departed: 1970 Yamaha R5A, 1971 R5B, 1975 Honda XL250, 1983 Suzuki PE175, 1983 CB1100F, 1983 BMW R100RS, 1992 ST1100

                    Comment


                      Originally posted by Big T View Post
                      Steve,

                      Hope you're swapping out the primary chain and starter clutch also, while you have the two motors apart
                      Good approach Big T, I agree 100% and will add oil pump & secondary shaft & clutch hub too if they are the same. Here are the KZ550 entrails.

                      Other progress: Just pulled the trigger on a EBay Wiseco K615 & cylinder assembly from an 550LTD. The KZ550 parts bike has the angular fins which are not period correct.

                      Last edited by srsupertrap; 05-02-2017, 10:31 PM.
                      1979 GS1000E (44 Yrs), 1981 GPz550
                      Departed: 1970 Yamaha R5A, 1971 R5B, 1975 Honda XL250, 1983 Suzuki PE175, 1983 CB1100F, 1983 BMW R100RS, 1992 ST1100

                      Comment


                        I'd take all the guts you can and move them over. With only 6300 miles on that engine the internals should be in great condition.
                        Ed

                        To measure is to know.

                        Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                        Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                        Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                        KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                        Comment


                          Last week, I shipped a used KZ550 cylinder with a brand new Wiseco K615 BB kit to APE to have the cylinders bored. Corey, I finally followed your advice . I only later learned from Rapid Ray that Carolina Cycle does great work as well but with faster turns. Oh well.

                          After carefully numbering all the plain crank bearings, I have transferred the KZ550 crank bearing with 6300 miles to the GPz550 engine cases. It looks like the crankcase internals from the KZ550 are identical to the GPz550 too . . . so everything may be ported over.

                          I am struggling with what to do with the original GPz550 cylinder head which has had two valve jobs, the #1 NGK spark insulator breaking which required replacing both valves in cylinder #1 and the latest start up issue in March 2017 were the valves may have kissed piston #1 as the connecting rod let loose. Great history . . .



                          The easy solution is to use the 83 KZ550 cylinder head which is unmolested from the factory and still retains the original valve shims. This head could be easily freshened up with a valve job, port cleaning, new valve springs and valve stem seals and out last me. This 83 KZ550 came with CV carbs which also allows me to slip the Mikuni Flatslides TM27 directly into the stock boots, see below.



                          This solution is appealing because the carburetor adapters the PO had machined (81GPz550 & Many 80-83 KZ550 came equipped with TK22 Slides) are not spaced correctly. For example, most Suzuki GS carbs are spaced 77-93-77mm. When the carb spacing is incorrect the only thing to give is the carb boot. Installing the above carbs in the original GPz550 cylinder head is a feat of strength requiring heat gun prep and JB penetrating oil. Just more evidence the PO did his best.

                          My only reservation is the 83KZ550 cylinder head has a different casting and looks different than the 81 GPz550. The cylinder fins are not rounded but instead angled at 45 degrees. I know I would hear the comment its got the wrong cylinder head . . . thoughts?
                          Last edited by srsupertrap; 05-18-2017, 12:22 AM.
                          1979 GS1000E (44 Yrs), 1981 GPz550
                          Departed: 1970 Yamaha R5A, 1971 R5B, 1975 Honda XL250, 1983 Suzuki PE175, 1983 CB1100F, 1983 BMW R100RS, 1992 ST1100

                          Comment


                            Steve,
                            You should plastigauge the crank bearings after moving the bearing shells and crank over into your cases. I think the cases have bearing size codes stamped into the cases somewhere too so you may want to investigate that detail. Bottom line is that different cases take different size bearings so don't take anything for granted.

                            I'd use that new head. As you say, it's factory fresh and should clean up like new very easily. The fact that the carbs will fit up better is a bonus as well as you know. As for the valve springs, I'd compare the springs that came in your engine to try to figure out if they are HD type to match the cams or just stock.

                            Looks like you are doing a nice job. Keep going...
                            Ed

                            To measure is to know.

                            Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                            Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                            Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                            KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                            Comment


                              eventually you'll want to put some Zephyr plastics on the bike.
                              HAHAHAHAHAHA
                              1983 GS 550 LD
                              2009 BMW K1300s

                              Comment


                                Morning Steve. Terrible luck with the motor, but it looks like you've hit paydirt with the donor bike. Might look tatty, but take what you need and hide it in a corner. I can guarantee you'll need to re-visit!
                                GS750EC, GS1100E, GS1150EG, Harris Magnum 2 (GS1170E motor), GSXR750F, Mk1 GSF1200, and finally Mk1 GSF600.

                                Comment

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