Announcement

Collapse
No announcement yet.

1981 Kawasaki GPz550: Restoration

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

    Originally posted by Corey View Post
    You are progressing well with this project, and will enjoy the results with no regrets, right?
    Well the pivotal decision was made back in March. The options were to part out the GPz550 project or 2. Throw additional money at it to make it whole again. I made the decision to go with #2 and thankfully the KZ550 parts bike came along and largely offset the project cost. I have certainly have learned more and met more good motorcyclists along the way. So of course no regrets.

    I need a damn 81 GPz exhaust cam with the tach drive. For the rest of the readers, I sold the Moriwaki mystery cams to fund the project because the stock GPz camshaft have approximately .325" lift while the Moriwaki camshafts I had measured .335"lift. Later realized 82 & on GPz550 used electronic tachometers so those GPz exhaust cams don't help. Corey wanted me to install Megacycle Cam 478-60 grind with .410 lift. Lots of interesting discussions with the guys on The GPz550 Forum about camshafts.

    Lou D's website is great reading too with lots of valuable GPz information http://gpzweb.s3-website-us-east-1.a...com/index.html
    Last edited by srsupertrap; 09-12-2017, 10:28 PM.
    Steve

    1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

    Comment


      I have read the GPz550 starter clutches can cause problems so last weekend I rebuilt mine


      Those allen head screws are torqued to 25 Ft-Lbs & loctitied


      Used the secondary shaft that not's not going back in the motor to grab onto with a pipe wrench

      Disassembled with new replacement dampers


      New pins rollers and springs. Not sure what actually fails but seemed like the wise move to replace parts while its easily accessible.


      Perhaps I will rebuild the original GPz550 starter clutch, someone on the The GPz550 forum was looking for one




      Cannibalizing the KZ550 transmission shift forks too. Hard to see but the GPz550 shift forks have more visual wear across the width than the KZ550 shift forks.

      Finally cannibalizing the KZ550 shift drum, overshifter lever, shift shaft because the original GPz 550 gear shift lever threads were damaged
      Last edited by srsupertrap; 09-12-2017, 11:20 PM.
      Steve

      1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

      Comment


        Ready to bolt the crankcase halves together after work. I ordered Kawabond #5 from Powersports Warehouse.com and it's back ordered. I still have a tube of ThreeBond Grey from 2014. Any reservations on using the older ThreeBond Grey?
        Steve

        1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

        Comment


          As long as the Threebond is properly tacky, it should work

          It's all the same stuff-Yamabond, Honda and Suzuki
          1978 GS 1000 (since new)
          1979 GS 1000 (The Fridge, superbike replica project)
          1978 GS 1000 (parts)
          1981 GS 850 (anyone want a project?)
          1981 GPZ 550 (backroad screamer)
          1970 450 Mk IIID (THUMP!)
          2007 DRz 400S
          1999 ATK 490ES
          1994 DR 350SES

          Comment


            Buttoned up the crankcases this weekend, torqued the connecting rod bolts & new crankshaft seals




            ThreeBond sealer




            Went together real easy. Bagged all the bolts when disassembled. Torqued to spec with T-wrench


            Next secondary shaft, oil pump & pan

            Last edited by srsupertrap; 10-03-2017, 10:23 PM.
            Steve

            1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

            Comment


              Tight fit for the starter clutch with tighter HyVo chain


              Install the KZ550 secondary shaft



              Loctite the two oil pump screw & bolt



              New gasket & o-ring seals & primed the oil pump.


              S/B ready to install in the frame
              Steve

              1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

              Comment


                New seals for the countershaft cover


                Permatek Black RTV


                Not going to stay that shiney



                Should be ready to install
                Steve

                1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

                Comment


                  I decided to make more progress and install the engine on Sunday. I called up Ray (Ghostgs1) to see if he could help out and less than an hour later he's at my garage helping me install the GPz engine. Less than 45 minutes later we got the engine installed. Big Thank You to Ray for dropping what he was doing on a Sunday.




                  Considering what type of break in oil I should use now that the weather is near freezing overnight. Perhaps Castrol 10W-40?
                  Last edited by srsupertrap; 10-17-2017, 11:35 PM.
                  Steve

                  1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

                  Comment


                    Originally posted by srsupertrap View Post
                    Considering what type of break in oil I should use now that the weather is near freezing overnight. Perhaps Castrol 10W-40?
                    Don't know about what oil to use (it's a bit of a "religious topic" anyway ) but wanted to say great work on the engine!
                    GS850GT

                    Comment


                      Originally posted by psyguy View Post
                      Don't know about what oil to use (it's a bit of a "religious topic" anyway ) but wanted to say great work on the engine!
                      Thank psyguy for the complement, not taking any short cuts. Oil is controversial topic maybe I will just review the threads elsewhere and review some old MCN engine oil evaluations. A little more progress during the week.

                      Barnett Extra Clutch Plate kit installed which came with the bike. Clutch Hub nut torqued to 98 Ft Lbs



                      Moving to the other side. Torqued the generator rotor to 50 Ft-Lbs and secondary shaft nut to 34 Ft-Lbs.



                      Starter is already installed. Starting to look like an engine again!
                      Steve

                      1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

                      Comment


                        Originally posted by srsupertrap View Post
                        Barnett Extra Clutch Plate kit installed
                        I installed one of those that ate up my basket. Coulda been the way I rode it. Have a tendency to brake down shift. Springs were waaay to stiff for me.

                        I dont even want to say it out loud but would hate to see something else go bad. This has been the most excruciating build ever on the GSRs. and now all the old pics are gone. If this ever has a happy ending you need to put it all down in a book. "The Murphy Bike Build"
                        Last edited by bonanzadave; 10-21-2017, 12:35 PM.
                        82 1100 EZ (red)

                        "You co-opting words of KV only thickens the scent of your BS. A thief and a putter-on of airs most foul. " JEEPRUSTY

                        Comment


                          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.
                          1979 GS1000S,

                          1982 Honda CX500 Turbo, 1982 Honda MB5 w/CR80 motor, 1977 Honda "nekid" Goldwing, 1976 Honda CB550F cafe', 1972 Honda XL250 cafe'

                          Comment


                            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!
                            Ed

                            To measure is to know.

                            Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                            Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                            Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                            KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                            Comment


                              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!

                              Comment


                                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.

                                Last edited by srsupertrap; 10-25-2017, 09:07 AM.
                                Steve

                                1979 GS1000E (45 Yrs), 1981 GPz550 (11 Yrs)

                                Comment

                                Working...
                                X