1981 Kawasaki GPz550: Restoration

[nvr2old]

I road raced a VF500F Interceptor several times in the 750 production class..and got on the podium every time. Those babies are sweet..they haul a$$ and they handle like they're on rails. I would embarrass the 750s in the tight stuff, and they could just nip me down the straights. Amazing bikes to this day.

[srsupertrap]

I read in Motorcycle Classics recently, the Honda VF500F Interceptor ended the GPz550 box stock racing domination.

[Rob S.]

...83 gpz550h1...what a brilliant bike love gpz kwaks

Cycle World called the GPz550 the first production bike that could be raced completely stock, right out of the box.

Writing about the 1981 GS1100E Suzuki, they said, "it didn't create the visual excitement of a Kawasaki GPz..."

I had a 83 gpz550h1 my first 4 stroke bike and a ypvs yam killer what a brilliant bike love gpz kwaks

[Burque73]

This one's a little closer, and cheaper. Right next door to me in fact, if you're at all interested in another one?

https://albuquerque.craigslist.org/mcy/d/1982-kawasaki-gpz550/6711676703.html

[srsupertrap]

The GPz is running really good, starts rights up, charges and the Mikuni smoothbores carbureate well even at altitude. The GPz is a joy to ride around town because its so much lighter than my GS1000. I am still getting used to the GPz gearing which seems like it could use a 7th gear for highway riding. Overall its a runner again instead of a garage project. Still have to replace a fork leg seal, winterize it etc. I did change the oil at around 75 miles.

I got this C/L link from Corey, 1982 GPz550 in your neck of the woods titled "$2,500.00 Bassani Exhaust". Looks to be a safety wired GPz550. Cheers

https://fresno.craigslist.org/mcy/d/1982-kawasaki-gpz550/6730096849.html

Any end of summer updates? How's the bike running now?

[srsupertrap]

Thanks Ed & 2Bracing for SH775 detail. I have to read up on SH775s because I am behind the times but then again I like older motorcycles. Since I already own a 82 GPz550 R&R which is the same design as the 81 model but has a different connector/ terminals. I placed a EBay order for 1/4" brass male connectors (China) and a crimper and will retrofit the 82 R&R and see if it regulates VDC.

Mean time I sent out the V&H exhaust for media blasting. Removed the baffle and found rust on the outside of the fiberglass packing. Blasting resulted in pin holes in the muffler. Diffuser can had rust holes also requiring repair. Header was pitted but solid. Here are those pics of the process:

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BTW what adhesive would you use to reattach the V&H logo? The old adhesive was very thin, flexible and black

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The guy blasting tried his hand at welding a cover, not much material led to the following or he didn't know what he was doing. On the underside, street facing

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No experience with V&H muffler packing so I removed about half of the fiberglass. For those who know add more?

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Plan to install this when oil filter change is due.

[2BRacing]

SH775's are OEM on Polaris side-by-side 4 wheelers. That is why they have mud on them!
At least that shows the ATV was running at the time it was wrecked!

[Nessism]

Is there a thread which lists current motorcycle make & models which come equipped with SH775s. The Ebay SH775 you linked looks weather worn, probably works fine though. Second does the SH775 bolt mounting spacing line up with the Kawasaki R&R bolt mounting spacing?

The SH775 is quite a bit larger than the typical OEM shunt type R/R. It won't directly interchange, but it's a big step up in terms of more modern technology.

[srsupertrap]

Is there a thread which lists current motorcycle make & models which come equipped with SH775s. The Ebay SH775 you linked looks weather worn, probably works fine though. Second does the SH775 bolt mounting spacing line up with the Kawasaki R&R bolt mounting spacing?

[Nessism]

https://www.ebay.com/itm/RZR-800-Voltage-Regulator-Polaris-OEM-11-14-1121/163176558872?hash=item25fe14b118%3Ag%3ALrwAAOSwNydbX1as&_sop=15&_sacat=0&_nkw=polaris+regulator&LH_ItemCondition=4&_from=R40&rt=nc

[srsupertrap]

I thought this would be a quick swap: Discard the EBay flywheel which measured lower voltage output and reinstall the KZ550 parts bike flywheel which went smoothly. I bought an open box Rick's KZ550 stator shown installed but it didn't slip right in. The rubber grommet width was 1.25mm wider than the OEM stator grommet so it wouldn't fit. Broke out the dremmel and milled the rubber down till I could force it in. Before I could do that the rubber grommet was not positioned correctly along the three stator wires. Sprayed the stator wires with penetrating oil and then inch the rubber grommet into the correct position. I also had to trim the wire conduit cover too. I suspect this stator's wires were not terminated in the correct position.

[IMG][/IMG]

Ops check in the garage today. Initially I saw battery voltage then after running at 2500 rpm it jumped into the 14.5VDC and then climbed into the 15.2VDC values. I guess the Shindegen regulator isn't. The picture is suppose to show 14.67VDC. I also have a 82 GPz550 Shindegen R&R which I wanted to "quickly" install and see if it would cut off/ground the voltage. Not so much, the 81 GPz/KZ550 R&R connector has male connectors while the 82 has female connectors and uses a different 6P connector to boot. To use the 82 R&R I pushed the terminals out but found I didn't have flat male connectors.



Do have 50 pairs of 4.00mm brass M/F bullet connectors.

[Nessism]

Steve,
Your bike is three phase but the 1980 KZ550 used a one phase charging system. Can't remember what year your parts bike was but you need to use a three phase R/R. According to partzilla the flywheel rotor is the same for all years so apparently there are no magnet differences.

[srsupertrap]

Steve,
You are experiencing a very similar situation to what I went through with my KZ. I tried two different used stators, three different R/R's, and still couldn't get the charging voltage up. Finally bought a new Rick's stator and SH775 and bang, 14.5 VDC @ 5000 rpm.

Looks like Ed was right again. I installed the shiny used EBay Flywheel this last weekend. Tested the stator ouput and the VAC output dropped from 53 to 50 VAC so I ordered a Rick's stator which should be here Friday. I will install the original flywheel while I am at. Fingers crossed for charging health