Announcement

Collapse
No announcement yet.

1981 Kawasaki GPz550: Restoration

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

    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.



    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

    Last edited by srsupertrap; 10-28-2017, 12:33 PM.
    Steve

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

    Comment


      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.
      Last edited by srsupertrap; 11-04-2017, 09:29 AM.
      Steve

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

      Comment


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







        Steve

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

        Comment


          This is a great build. Keep it up!
          1982 GS1100EZ, second owner, 11,000 miles
          2000 XR650R, plated

          Comment


            Originally posted by srsupertrap View Post
            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.
            #1: 1979 GS 550 EC "Red" – Very first Bike / Overhaul thread        New here? ☛ Read the Top 10 Newbie mistakes thread
            #2: 1978 GS 550 EC "Blue" – Can't make it a donor / "Rebuild" thread     Manuals (and much more): See Cliff's homepage here
            #3: 2014 Moto Guzzi V7 II Racer – One needs a runner while wrenching
            #4: 1980 Moto Guzzi V65C – Something to chill

            Comment


              I would do what ever the factory did... esp. if you're using factory gaskets.
              1980 GS1000G - The Beast - GOING... GOING... yup, it's gone. I'm bikeless !!! GAaaahh !!!
              1978 KZ1000C1 Police - GONE !
              1983 GPZ750, aka ZX750A1 - restored, fresh paint... Gave it back, it was a loaner !!!
              Check My Albums for some of the 30+ headaches I've dealt with

              I know -JUST- enough to make me REALLY dangerous !


              Comment


                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]
                Last edited by srsupertrap; 11-15-2017, 11:48 PM.
                Steve

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

                Comment


                  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.
                  Last edited by srsupertrap; 11-19-2017, 12:09 PM.
                  Steve

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

                  Comment


                    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.

                    Comment


                      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

                      Steve

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

                      Comment


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


                          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

                          Last edited by srsupertrap; 12-05-2017, 11:29 PM.
                          Steve

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

                          Comment


                            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.
                            Larry

                            '79 GS 1000E
                            '93 Honda ST 1100 SOLD-- now residing in Arizona.
                            '18 Triumph Tiger 800 (gone too soon)
                            '19 Triumph Tiger 800 Christmas 2018 to me from me.
                            '01 BMW R1100RL project purchased from a friend, now for sale.

                            Comment


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

                              Comment


                                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!
                                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

                                Working...
                                X