1981 Kawasaki GPz550: Restoration

[srsupertrap]

11/3 Weekend Update:

Replaced all the petcock gaskets & seals last weekend so yesterday I flushed the tank and installed the petcock for a leak test. The GPz petcock is vacuum operated like a the GS1000



No idea what the tab on the back of the gas tank does. Perhaps it sits against the long gone airbox?


New vacuum & fuel line . . .



Like the RS34 SmoothBores the guys at Mikuni did not provide enough clearance between the top of the Carbs & Petcock



The paint is really bad shape but at least it looks like a GPz550

Rusty & dented. Probably needs professional help

[blowerbike]

Wouldn't mind seeing some (a lot of) pics of that beast.

It just barely edged mine out in the 1320 and prevented Suzuki from three-peating as World's Quicket Production Motorcycle.

here Rob..
i won't clutter his thread.

http://www.thegsresources.com/_forum/showthread.php?227279-APE-GS1100-Cyl-Studs&p=2122850#post2122850

[Rob S.]

Hijack

My 82 GPz1100...

Wouldn't mind seeing some (a lot of) pics of that beast.

It just barely edged mine out in the 1320 and prevented Suzuki from three-peating as World's Quicket Production Motorcycle.

Score indeed. Nicely done.

[srsupertrap]

Waiting impatiently for Steve to slap the exhaust on and feed this thing some gas

Well the petcock has been soaking in Berryman's and I just started a new job with a medical device manufacturer outside Boulder, CO.
But I did score a NOS Supertrapp muffler for the GPz 550 for $60 shipped





Now I need Supertrapp header for a 80-83 KZ550 or 81 GPz550
A coworker mentioned he has a CB400F that has been sitting for 15+ years

[Big T]

Waiting impatiently for Steve to slap the exhaust on and feed this thing some gas

[srsupertrap]

10/18 Progress: Meter Assembly . . . broke the original trip reset wheel trying to remove the covers. That knob screws on CW and is never meant to be removed.







Finished the Tachometer. Right of the Tachometer is a roller chain pin I got from the Ford Norfolk Assembly plant. During summer shut down, they were replacing a section of worn chain used to move F150's along the assembly line. I asked a pipefitter if I could have the used pin. He said sure . . . that thing must be hardened to hell because when you hit something with it the other pieces always bends.





New speedo & tach cables. The tach cable is from Motion Pro and too long





Ops Check: The horn button does not operate the horn & the headlamp indicator light is On.

[srsupertrap]

Looking awesome Steve! Amazing work! Please record a video after you get it going!

Ed, I still have not tackled reinstalling those stainless steel bezel rings on the speedo & tach . . . that might be the hardest job of all.

[Nessism]

Looking awesome Steve! Amazing work! Please record a video after you get it going!

[srsupertrap]

my 82 GPz1100 worm gear adjust backwards also....really had me cornfused....

I am glad I am not the only one. I like the GPz clutch cable routing

Here are the latest photos, I spent an hour rummaging through Advanced Auto Parts thermostat gaskets looking for one that was close to the intake manifold. Only required a little dremel modification



Before there was only one gasket on the engine side and gobs of red RTV sealing the boots. Those adapter plates were home made too. The workmanship is interesting . . .we will see if its air tight



Got the 27mm Flatslides installed, the new OEM throttle cables open and close fully with plenty of slack

[blowerbike]

my 82 GPz1100 worm gear adjust backwards also....really had me cornfused....

[srsupertrap]

I will be jumping around a bit here because waiting for more parts from Powersports Warehouse . . . These guys are cheaper but very slow on delivery with no communication

Installing the Countershaft sprocket cover


New release spring too . . . After reading the manual's procedure on adjusting the clutch cable, I finally got the clutch to work but only after turning the adjusting screw on the C/S cover out all the way & then turning CW 1/2 turn??? The manual states loosen everything and turn the screw in CW. What ever it works



Using FJ1200 starter solenoid cable for the battery ground & Siemens PBX Battery back up cable for positive battery cable


I don't know where the White with Black trace wire connects to (Right of my thumb)? This wire comes off the Fuse Block mounted behind the gas tank.


Picture of Coil Wiring . . . much cleaner


Other side


C/S Cover installed, Allen heads securing all the engine covers. I was missing a 12mm washer seen behind the shift lever.

[srsupertrap]

I got interested the other night and went into the garage to look at my modified 81 Cam Chain tensioner and unmolested 82 cam chain tensioner I bought from Joe Whelan shown side by side. When I took apart the modified 81 tensioner I found the perpendicular crosswedge & spring which puts the force on the main plunger were both removed.



This photo of the modified 81 Cam Chain tensioner is fully extended



This photo of the modified 81 Cam Chain tensioner is fully retracted which takes some force to compress. From what I can see now, the bolt screwed in the back of the 81 Cam Chain tensioner prevented the plunger from backing away from the Cam Chain Rear Guide. The bolt did not push the plunger solidly in against the Rear Guide causing accelerated wear as I once thought.



I will be installing the 82 Cam Chain tensioner with a new main plunger spring shown side by side with the old ones

[srsupertrap]

Week End Update for 9/28: Dialing in the cams . . . applying Loctite to the intake cam sprocket bolt. Kevin Cameron would approve.



Used the Web Cam pdf this time, .050 either side of cam lobe etc. Used the vice grip clamp & indicator for the first time. This method took forever to get repeatable measurements because the swivel arm would not stay locked in place.



I used the APE 12mm tool either side of TDC to find truth. The factory GPz TDC mark was spot on.



I set both Intake & Exhaust to 105 C/L. I found installing the Moriwaki Exhaust cam very difficult even when using the extended vice grips to compressing the cam into the head. Unlike my Suzuki which has Andrews cams and pretty much snaps into place, the Moriwaki cams took 4-5 repetitions with the vice grip to get fully seated. The uneven pressure of the cam ended up stripping out several more cam bearing threads. Crappy design for both Suzuki & Kawi DOHC . . . I should have replaced them all with M6 helicoils when the head was disassembled.



New Plugs & Wires

[srsupertrap]

Since I never had the cam card/data sheet & installation instruction etc. I am struggling with where to set the C/L angles.Both cams have 8.25mm of lift ( Measure across lobe - Base Circle ).
Dale's Moriwaki Ad


gave specs for both KZ550/GPz550 Street & Race Cams. No idea what year it was published etc. & not the specs for the cams that are installed in my GPz550.

For the street cams the ad states, the Intake opens 15 BTDC & closes 45 ABDC. Exhaust valves are opened 40BBDC & closed 13 ATDC. The intake lift is 8.2mm (close to mine 8.25 Actual) while the exhaust lift is 7.5mm (much less).

The race cams are more aggressive . . . feel free to review the Pdf

I am thinking the logical step is to use the Street Intake Open & Close figures of Open 15 BTDC & close 45 ABDC because the 8.2mm intake lift is closest to the actual lift of 8.25mm.

Makes sense right?