1981 Kawasaki GPz550: Restoration

[nvr2old]

Gettin' close.... Looking forward to the finished product.

[srsupertrap]

Thanks Corey, I might have found one of those T-shaped connectors. More progress over the warm Thanksgiving holiday



I used Threebond 1184 on the half moon gaskets



That damn exhaust header may tuck in tight but the exhaust port spacing between 1 & 2 and 3 & 4 cylinder fits like crap. If I ever find a Supertrapp header I will sell it in a second and be happy to have a centerstand back.



Be installing the cables & K&N's tonight

Hi Steve. Great progress.

Could you elaborate more on that connector? I will see if it is used on my A Model. Here to help.

[srsupertrap]

Some more progress, assembly should move pretty quickly. Decided to use Valvoline 4T 10W-40 for initial break in



The cylinder fins are polished like the original 1981 GPz cylinder head


Torqued to 17 Ft-Lbs


Camshafts went in no problem, liberally lubed all contact surfaces with CRC assembly lube, check valve lash later today



Need a T electrical connector like the one below, If you have an extra please PM or let me know.

[srsupertrap]

Yep using factory gaskets, so I will skip the black RTV around the cam chain tunnel.

Regarding cams, I sold those Moriwaki cams and just received a set of 81 GPz550 cams on Monday which is the only GPz model which a tachometer drive. The later H1, H2 & ZX550's all used electronic tachs. I am using a ZX550 cam (Same .325 lift & different duration) for the intake which I bought from Corey and 81 exhaust cam which Corey also located for me on EBay. Last night I benched shimmed the exhaust cam. What caught my attention while bench shimming both cams was the fact that the shim size before and after the "valve job" did not really change. In some cases not at all . . . Hmmm



No longer using the adapter plates for the Mikuni smoothbores but decided to use the Felpro gaskets with a film of black RTV to fill in the uneven surface on the carb boots I purchased back in 2014. Installed 8 new allen head screws


[IMG]


Installed some of those compressible fibre exhaust gaskets. I purchased them from an EBay seller in the UK and unfortunately found the OD was too large. Although the seller sent me replacement gaskets, apparently my experience was not an isolated case. I like the design but the quality sucks . . .

[/IMG]

[exdirtbiker]

I would do what ever the factory did... esp. if you're using factory gaskets.

[roeme]

Weekend update. Wonder if I should use any RTV on the base gasket before I move onto the cylinder head

Friend of mine recently replaced the base and head gasket on his Z500 and did use RTV.

[dweller]

This is a great build. Keep it up!

[srsupertrap]

Weekend update. Wonder if I should use any RTV on the base gasket before I move onto the cylinder head

[srsupertrap]

Here is my version of the You Tube piston ring grinder; I switched to a finer grinding wheel for more control. Price was right!





All the top rings now have .013" piston ring gap, second ring measure .017"



Bought a EBay piston ring expander but its too big for the Wiseco .8mm rings



Installed the new Wiseco 615 pistons too



PS: Still looking/need 1981 GPZ550 camshafts (Tach Drive). These cams are identified by two circular grooves on both In. & Ex Cams adjacent to the Cam Sprocket.

[srsupertrap]

I could buy a Proform 66785 Manual Ring Grinder on Amazon/Ebay but delivery pushes assembly out. Checked out You Tube this morning and found this video which makes use our the handy dremel tool.

https://www.youtube.com/watch?v=YSTPdZA3KV8

I purchased a Dremel grinding kit about a decade ago, I have used lots of Dremel 420 cutting wheels but never anything from the kit. I decided to test the grinding ability before moving onto piston rings. Pulled out the damaged connecting rod, s/b steel.



Looks like I have the right equipment just have to fixture everything. Wiseco rings are only .8mm thick

[srsupertrap]

Thanks Dave, Larry, Ed for following along all these years and keeping me motivated too. Zaddict welcome to the GS Resource Forum as well and thanks for the encouragement. The GPz sure is lighter than the GS1000 and I am looking forward to riding instead of wrenching. I am feeling the end of the project is in sight. On Saturday I was hoping to get the pistons installed.

Installed the clutch cover, previously slotted the Dyna S ignition for additional range



Installed the C/S cover and generator cover too



Next I checked the ring end gap which I could have done months ago. First square off the rings using the piston


The top ring end gap measured .010" across a four which is tight ( suppose to be .012" min). The second ring measured by .017" across all four. I need a piston ring grinder for the top ring which I don't have. Last go around I borrowed Chris's [Cdnoel] grinder down in Colorado Springs.

PS: Any local options, rentals etc? I can order a Piston Ring Grinder on-line but delivery is likely a week out . . . Thoughts



I spoke with a Wiseco Tech this morning, he recommended a top ring gap of .013" because the calculations are minimums. He said the .017" for the second ring was fine and will reduce flutter.

I joined this forum just so I could say a few words of encouragement. I really admire your craftsmanship and tenacity. Plus I really, really want to see this bike running. It's going to be an absolute blast to ride when you're done. I have an old zr550 I'd like to give a similar treatment at some point. Keep it up!

[Nessism]

Using Chrome browser and the "photobucket" extension and most of the old photos show up. This has been a great thread that shows Steve's tenacity; Sh*t happens, what's important is how we deal with it!

[nvr2old]

Boy, no kidding. I have watched this build from the start and I have to compliment you on your tenacious and never-ending faith in getting this bike done, and done correctly. Most people would've called it off many months and dollars ago. Riding it will feel SO good.