1981 Kawasaki GPz550: Restoration

[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]

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]

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

[dweller]

This is a great build. Keep it up!

[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.

[exdirtbiker]

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

[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]

[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.

[Corey]

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]

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

[nvr2old]

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

[srsupertrap]

Same here Larry, with some mild weather I finished up on Sunday. Those Mikuni smoothbores were only made for the GPz550 not exactly a smart marketing move by Mikuni. I have also heard the stock GPz throttle cables don't work on these carbs but I have never had an issue.






The Kz550 parts bike donated the owner manual and plastic case which fits neatly in the cowl



Old New Mexico plate circa 1994 when the PO likely parked it. My new plate. Still have to modify
chain guard so it doesn't contact the rear wheel

[alke46]

Man, this thing really turned out nice. Worth a lot of coin in this condition, I would think.

You must be proud of all your efforts and your talent level and attention to detail is very admirable.

[Zaddict]

Inspirational job, really beautiful work. I learned a bunch reading this thread. That thing is going to be so much fun to ride!

[Nessism]

Won't be long now Steve! Can't wait for the video of the first start! You are taking one aren't you? Ha ha, easy for me to say. I've never done it. The first ride may require a snowmobile suit too eh?

Looking good and fingers crossed for a successful transition from project to runner!