81 GPz550 / ELR

Thanks !

The 550's are great bikes, I agree. I've had a few, the first was an '81 A model, which I bought in '85.

As far as the fork height is concerned, I think that the forks on your LTD are about an inch longer than the std model, so your change probably got you near the standard bike's geometry.
The forks on my bike are actually from a KZ1000, I've also raised the rear a bit, and swapped the 19" front wheel for an 18", so I'm not sure where I'll end up with my fork position.

....sitting on it's own wheels/tires/suspension for the first time!

I'm glad that I was able to beat the cold weather and get pretty much all of the paint work done before winter.

Getting the paint done before winter is a big thing.

I just started building a 82 kz1100a2 and I'm going to have a problem getting my body parts painted before winter. I should be able to get the frame done though.
My problem is I heat my shop with kerosene and that will cause base clear to orange peel. I'm either going to have to find a place with electric heat or wait till spring.

Mike, how do you find the time? I can barely get up the time to check the oil and fill the tires. :blush:

Looks awesome!

True Lou, I have been spending a lot of time, you've got a couple completed project bikes under your belt, so as you know, you just get it done. I'm ready to back off a bit now that I've got the weather sensitive stuff mostly done. I've probably spent about 100 hrs on it over the last month. Another hundred or so over the winter and I should be just about done.

It's hard to believe it's been 3 1/2 mos since I posted about this. Winter sucks !!

I've made a small bit of progress. I got an '82 GPz750 front fender, the 550 fender that is pictured is for offset axle forks and doesnt really fit the straight legs forks that I used. I've also gotten the carbs ultrasonically cleaned, and I found a nearly NOS '81 GPz550 seat.

I'm still hoping to have this bike roadworthy by the beginning of riding season (5/1), so I've got to get back in gear and start getting things done. I still have to make or modify the mounting bracket for the headlight, fairing, and instruments. they will all be somewhat different from stock 550 parts because I'm using KZ1000 Police triple clamps/forks. I also have to do the wiring, which entails fitting a ZR550 wiring harness and associated electrical componentry into the spaces that are available on the GPz chassis. I'm using an '82 GPz550 electronic instrument cluster, so that will have to be pinned out and mated to the ZR harness also.
Also, I still need to get new chain/sprockets, cables, and a gel battery (not taking any chances with my paintwork)

mjg15 wrote:

Thanks for the encouragement. I want to finish it by spring, which is realistic even at a moderate pace. The frame alterations and some machining to correct some axle/wheel fitting issues are the only things that will be handled by others. Once I get past those hurdles I will be able to work at my own pace. I have all the major parts on hand. I have to order the small stuff like steering and wheel bearings, brake lines, chain/sprockets, cables, tires etc.(ouch..., thats about a grand or so )

Macdroid, you are right about the 550's getting little love, they seem to be the unwanted step-children of the KZ line around here .

I'll post updates as they happen.

i actually like the lines of the 550s better than the kz650,same thing with honda night hawk with the sport fairing.
reminds me of a baby z1r i guess! :laugh:

did you need to change any mounts to make the motor fit?

PLUMMEN wrote:

did you need to change any mounts to make the motor fit?

Motor bolts in. They are pretty much the same motor. The finning on the head is different, and so are all the case covers, but the cases and mounting points are the same.

You're right, the 550 does look like the Z1R, with the same square tank style. Very clean and simple.

I don't want to burst your bubble, but you might want to look into replacing some of the original gaskets on that low mileage motor, before you start it up. Old seals and gaskets will seep, I have found out first hand, and not having to take that engine out to do it once it's in, might be something to think about.

-Head gasket, and side oval o-rings
-Valve cover gasket and cam end plugs(once you check the valve clearances, this will be buttoned up anyways)
-Oil pan gasket and o-rings(you can clean whatever is in the oil pan out, as time will have some kind of sludge in there)
-Left front trans cover gasket and both oil seals(this is a very common leak point)

These can be done with the engine still in the frame.

Just some advice here.

Project is looking good!!! I wish I could fab like some of you do, my race bike upgrade would be finished already. :S

Corey,
Thats good advice for sure, and I have given thought to it. I have had a few problems with that before on some of my other old Kaw's, in fact they pretty much all seep some oil in one place or another. The problem is that I have a problem; I can never put anything back together stock once it comes apart. I did plan to do a valve adjustment and retorque the head, so for an extra hour of work I guess that it would make sense to pull the head and do the head gasket at the same time, with no carbs or exhaust installed it will go quickly.

How is your racebike update coming ?

I've been doing a little work on my SM racebike project too, but it has been so cold here that it's just not enjoyable to deal with the cold garage (and not practical to heat it).

I have tried the retorquing thing, and it doesn't, or didn't work. Replace the gaskets, and be done with it. The places I've listed are where I've seen it happen on used engines, and ones with low mileage as well.

Yep, I think most of us can't leave well enough alone. It's bread into us.

Racebike won't have the EX650 changes I want before AFM Round 1 March 19-20 at Buttonwillow, so I'll buy a new set of Avon Race Rubber, Galfer Green Pads, finish the Tarozzi Universal Rearsets, rebuild the front calipers, and do the basic race prep stuff. I will be installing and degreeing the Megacycle Cams in the current 615 engine, then getting it dyno'ed again at MCE Racing. Might reinstall the stock fairing too.

Now back to the topic at hand.