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1981 Kawasaki GPz550: Restoration

Waiting impatiently for Steve to slap the exhaust on and feed this thing some gas
 
Big T said:
Waiting impatiently for Steve to slap the exhaust on and feed this thing some gas
Click to expand...

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
 
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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
 
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Awesome work Steve! Count me as another waiting for you to feed this beast some gas!
 
Big T said:
Waiting impatiently for Steve to slap the exhaust on and feed this thing some gas
Click to expand...

I am in the process of moving BUT being a gearhead I found this 82 GPz on C/L and could not resist for $150, there's a diamond in there. The CL link will be deleted soon. The guy I bought it from was moving too :)

http://cosprings.craigslist.org/mpo/4752935486.html



A Bassani Superbike pipe might be the finishing performance touch. It's a 1984 model so likely a bracket will need to be fabricated.



Everything else is 4 Sale ( Carbs, Airbox Body work ): Title in hand


 
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Dang. That pipe alone is worth way more then the cost of the bike. Nicely done. This bike is gonna be SO cool. Love the style of wheels on these bikes, painted a magnesium gold, they'd look like a pair of Morris wheels.
 
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Nice pick up Steve. Guess you don't have enough to do.;)

Learned something today which may serve you as well: the valve cover on my 750 has a rub block for the cam chain, and when you install the cover it contacts and deflects the chain. Your 550 has a similar rub block in the valve cover so you may want to check to see if the block depresses the chain between the cams like it does on the 750. In order to degree the cams on a 750 you need a cutaway valve cover to avoid upsetting the timing when the cover is installed. Hope this is not the case for the 550 but wanted to share.
 
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nvr2old said:
Dang. That pipe alone is worth way more then the cost of the bike. Nicely done. This bike is gonna be SO cool. Love the style of wheels on these bikes, painted a magnesium gold, they'd look like a pair of Morris wheels.
Click to expand...

Check this out . . . . 1982-83 NOS GPz550 Bassani system which recently sold on EBay for $475. Everyone was watching on the GPz550 forum it was bid up to $650 before sliding back to final price

http://www.ebay.com/itm/VTG-NOS-Bassani-Superbike-82-83-Kawasaki-GPZ550-Exhaust-Muffler-Racing-Pipe-4in1-/291300508069?pt=Motorcycles_Parts_Accessories&hash=item43d2dd01a5&vxp=mtr
 
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Nessism said:
Nice pick up Steve. Guess you don't have enough to do.;)

Learned something today which may serve you as well: the valve cover on my 750 has a rub block for the cam chain, and when you install the cover it contacts and deflects the chain. Your 550 has a similar rub block in the valve cover so you may want to check to see if the block depresses the chain between the cams like it does on the 750. In order to degree the cams on a 750 you need a cutaway valve cover to avoid upsetting the timing when the cover is installed. Hope this is not the case for the 550 but wanted to share.
Click to expand...

Ed,
Thanks for the information. Corey Clough the GPz550 forum administrator ( who has almost as many posts ) mentioned the same and posted some pictures of his cutaway valve cover. I did not not follow that procedure when I timed the cams. I did replace the cam chain, cam chain guides including the rub block in the valve cover and that rub block barely showed any signs of wear/contact. Since I had new OEM parts as a matter of principle I replaced it and the rest of them. Now I don't believe my cam chain was ever running tight considering how the PO modified the original cam chain tensioner ( the bolt he installed was not seated against the rear cam chain guide ).

I learned the following from Loudhvx which is most likely applicable to your KZ750 cam chain tensioner if its a "wedge type" cam chain tensioner. I didn't double check yours but Kawasaki just like Suzuki shared many parts across models. When you removed the GPz550 cam chain tensioner there is no screw like a GS tensioner which holds the plunger in place and the result is the plunger moves all the way forward taking up all the excess cam chain slack. Install the GPz550/KZ750 cam chain tensioner in that position against your new cam chain and your cam chain will stretch in short order because its exerting maximum pressure.

The correct way to install the GPz550 wedge type cam chain tensioner is to first break loose that 17mm nut that is perpendicular to the cam chain housing. Remove the internal wedge & spring. Next install the cam chain tensioner housing to the cylinder block with the main plunger. Secure the housing with the 10 mm bolts. Install the valve cover then finally installed the wedge, spring & cylindrical cover. The inserted Pdf states it better. When I was fiddling with the GPz550 cam chain tensioner on the bench I could not get the cam chain plunger to retract no matter what force I exerted. In other words the GPz/Kz wedge type cam chain tensioner is designed to extend but never retract.

http://home.comcast.net/~loudgpz/GPZweb/CamsKZZXZR550500400/CamsKZZXZR550500400.html
 
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Purchased this GPz gas tank on EBay last week. No perfect but better


Its dented by the emblem front screw hole







This needs help?
 
got a line on a clean 82
do no tlike em as much as the 81
sort of stuck in the middle of old school and repli-racer
 
JEEPRUSTY said:
got a line on a clean 82
do no tlike em as much as the 81
sort of stuck in the middle of old school and repli-racer
Click to expand...

Most say the 82/83 H-1/2 models were considered the best GPz550 models produced. If you can a good deal on the 82 go for it you can always flip it. 81 has roots in 70s
 
So are you riding it yet...? Hello...anyone there...:confused:
 
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I sat out the 2015 season sidelined with a rotator cuff tear which required surgery back in October. I can say you loose interest in motorcycles when you cannot lift your arm :) Just before I went in for surgery I sent out the entire set of Gpz bodywork to get repainted with an old codger on the south side. I will post pics when they return, hopefully worth the wait.
 
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