1981 Kawasaki GPz550: Restoration

[srsupertrap]

Thanks Corey, azr, nvr2old, harley10, Vmass, Sci85, Big T & winfield and I hope everyone is enjoying this because its therapeutic for me.

I received the OEM valve cover gasket from Ebay so I decided to see what surprises are under the valve cover.


Here is a picture of the cam chain tensioner, no way this can be stock right? I probably go back to stock since I won't be chopping the throttle at 10K



I removed the plug wires from the coils and found the smucklehead didn't even install terminal connectors. All four are like that.


Man this thing has a lot of bolts securing it. I removed the 2.2 Ohm coils to make room for the valve cover removal. More room than a GS



Thumbs down to the Kawasaki Engineer for placing the cam chain bolt directly under the horn with no access to remove it



A quick tap with the mallet and the valve cover pops free


The oil galleys are dry but everything turns smoothly, I fill em up with dino for the time being. Cam lobes look perfect.


Okay, I need help here . . . What cams are these? M "symbol" E. One is marked R1 while the other is R2. They don't look to radical Oh yeah it's slotted cam sprockets.

subscribed

[Vmass]

Very cool bike!

Best of luck with the project.

What a beaut! I love the half litre bikes and the gpz is a sweet one. I'd like to add one to my stable. I bet this one screams too. Keep up the good work.

[Big T]

Pipe looks like a Bassani to me ,very nice project,brian

Bassani has big "ears" where the header meets the mid pipe

That looks just like my Yosh, a split on the mid pipe where it slides over the header and the two rivets on the end where the badge used to attach

[srsupertrap]

Thanks Guys! I am going to do my best with this little red rocket. Azr, I have already purchased an OEM valve cover gasket but the rest of the order I am sending to Chris @Z-1.

Okay what can I do on Monday night? Put up the Christmas Tree or clean the K&N Air Filters . . . I will do both

Pipe looks like a Bassani to me ,very nice project,brian

[nvr2old]

Really cool bike. I've always loved the 550 GPz's. Great starting point. With only 3,000 miles since the rebuild, it should be fine, even after 27 years of storage. It'll be fun to see the progress.

[Big T]

looks good so far

Yosh pipes have a plate riveted to the can. Looks like the rivets are there

That thing will be a rocket.

As I mentioned before, get the Avons in 3.25/4.00 for the sharpest handling

subscribed!! Lots of fun mods on this bike, bet she's going to be crazy fast and fun for a 550. Are you using Z1 for all the engine gaskets?

[srsupertrap]

Wheeled my GPz550 into the garage today to begin the restoration/rebuild. It's been stored inside for 27 years and I would like to be done by June 2014. Yesterday by searching the net I discovered this GPz 550 is really a race bike (8rt Exagerration). The PO installed a 615 cc big bore kit, race cams, 26mm Flatslides, Yosh exhaust, Dyna Ignition with 2.2 grey coils and also stated the engine was balanced & blue printed. Today was tear down



First the seat goes, I will need new hinge pin and better yet an original 1981 seat.



Next the Flatslides go BUT they are stuck so I use the hairdryer


The slides are stuck so getting the throttle cables out was a PIA but they came off & will need a new cable because it frayed



I get the Flatslides off and look down the intake ports . . . looks shiney. I also notice the cam chain tensioner is not an automatic spring loaded factory jobbie.





Pipe is next to go, whoever installed it tightened the little 10mm nuts to the point where they bent the exhaust flanges. The outer exhaust stud is stripped that needs to be replaced too



The only marking I see on the "Yosh" pipe is KZ 51, KZ 52 etc on the header pipes. No Yoshimura marking?



Looks like a Yosh or RB Racing pipe. Have not tried to take it apart yet.

2/11/18: I contacted RB Racing & sent a photo in 2017 and received a reply the exhaust was not a RB Racing. Like Big T stated it's a Yosh



Next I install the centerstand I purchased from Joe (Jwhelan65) so I can work on this bugger



Two and half hours later I have reached a good stopping point. I need a rear fender if anyone spots one 80-84 KZ550 will work

I also want to welcome my friends from the GPz 550 Forum following this thread. I cannot post pictures on the GPz 550 forum so I decided to run two threads.

To Do List: Valve cover gaskets is on the way, have to ID the race cams so I can set the valve lash correctly. Z-1 order for other engine gaskets etc.