1982 Kawi GPz-550 Cafe Build

Discussion in 'Some Assembly Required' started by HuckIt, Aug 21, 2021.

  1. HuckIt

    HuckIt Been here awhile

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    Patiently waiting for parts to get back from paint, been three weeks and they finally made it into blast today, supposed to get coated early next week. With any luck be doing some assembly next weekend.

    In the meantime been taking care of loose ends like carb jetting, cables, etc

    And getting in a few dirt and street rides :ricky

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    #41
  2. HuckIt

    HuckIt Been here awhile

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    I guess I know what I'll be doing this weekend:happay

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    #42
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  3. motocopter

    motocopter Long timer

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    Nice! It all looks good.

    Not sure if you muscled the engine out of the frame or not, but consider putting the engine on it's right side and supported with blocks. Then lower the frame onto the engine. You can eliminate paint chipping. I did my former 750turbo like this. Inserted a couple of long engine bolts and then uprighted the frame with the engine.
    #43
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  4. HuckIt

    HuckIt Been here awhile

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    Great tip motocopter, I'm going to use it!
    #44
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  5. VX Rider

    VX Rider Long timer

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    Some split rubber how is also nice to put over the frame to prevent nicks
    #45
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  6. HuckIt

    HuckIt Been here awhile

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    Made some progress today:

    Reassembled the forks:
    PXL_20211002_191818130.jpg

    Added the seat pan molding:
    PXL_20211002_150424313.jpg

    And finally got the motor installed using @motocopter 's method. Worked great, still put tape on any bolts that were sticking out as its a really tight fit - but got it installed with no scratches so that's a win!
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    #46
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  7. motocopter

    motocopter Long timer

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    Thought you'd like to see a couple of pictures of my former '83 GPz-550. Took these in late '83 or '84.

    IMG_20211006_172615494.jpg

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    #47
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  8. HuckIt

    HuckIt Been here awhile

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    That's awesome! Such cool bikes...

    I was making decent progress on mine but realize last night I need to pull the motor back out to install the swing arm nut/bushings....ugh - thought they could go in afterwards but they interfere. Will tackle it tomorrow.
    #48
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  9. Nathan_66

    Nathan_66 Been here awhile

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    @'84 was when I was lusting over them and parents said 'NO!'. The 4-1 KERKER looks sweet on it! It was a big deal back then.

    Huckit, how's the search for the header going? Looking good so far! and good job not going the macho route lifting the engine haha
    #49
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  10. HuckIt

    HuckIt Been here awhile

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    Slowly but surely making some progress, pulled the motor last night (not all the way but removed all mounts and shifted it in place) to get the swing arm mount bushings installed.

    Got the swing arm/shock and triple clamps installed, and started on the wiring. Thinking the wiring will be the big project for the weekend.

    @Nathan_66 Had no luck finding a quality header, searched the interweb high and low about a million times, talked to some guy in San Diego that had one but wouldn't break it up from the parts bike he had for sale, and even registered and posted a wanted add on zrxoa.org at your suggestion but no luck. Ended up buying a MAC exhaust for a Zypher 550 that I think I'll be able to fit. The exit diameter is too small (its shoved inside the mid-pipe in the pic below), I'll either just add an adaptor to go from the 1.85" exit up to the 2.5" mid-pipe or maybe cut it back to where it is at roughly 2.5" and weld an end on there. The area at 1.85" diameter is 50% of the area of the four header pipes, where a 2.5" diameter exit is 89% of the four header pipes. Can't think of a reason the larger cross section wouldn't be better....

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    #50
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  11. HuckIt

    HuckIt Been here awhile

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    Good progress again today, all three brake calipers assembled with new seals, rear caliper and linkage installed, chain cut to length and installed. forks and clip-ons installed. Will get the front wheel, brakes, fender and lights on tomorrow and then time to tackle the electrical.....Can't put it off any longer

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    Also picked up a Bassani header today thanks to @Nathan_66, leaps better than the MAC one (hopefully I can return it). Needs some minor repairs and paint but so much happier to have a quality header that will flow properly!

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    #51
  12. 3legs

    3legs Real men ride sidecars Supporter

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    Keep up the good work @HuckIt. Looking great.
    #52
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  13. sruss67

    sruss67 Been here awhile Supporter

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    Looking really good, coming together well :rayof
    #53
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  14. Nathan_66

    Nathan_66 Been here awhile

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    A Bassani! Wow, that's going to turn out very nice restored. Great score!
    #54
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  15. motocopter

    motocopter Long timer

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    The Bassani looks good. I recall them being really loud. Maybe we'll hear this one soon!
    #55
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  16. HuckIt

    HuckIt Been here awhile

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    Making bits of progress every day....Doesn't seem like much in the pictures but lots of time going into it, wish there were more large things to install that would feel like progress.:-)

    Got the right length rear brake line in and installed as well as the reservoir:
    PXL_20211018_015612569.jpg

    Designed and printed a new fork dust cap that doesn't stick up so far since I'm using clip-ons below the upper clamp. The original design had bars mounted above the upper triple clamp and these long bolts(?) that would secure them to the forks. With the clip-ons below the clamps just need a dust cap in place since there is a piston type insert that seals inside the forks a few inches down that is held in with a retaining clip.

    Comparison to the original:
    PXL_20211016_230352590.jpg

    and the new ones installed (I plan to reprint them with finer settings so they look better):
    PXL_20211016_230444904.jpg

    Also started looking into the new (to me) Bassani can. I really only need the header since I have the Supertrapp slip-on but was debating on repairing it to keep the megaphone all the way out. But, I think I'm going to stick with the Supertrapp, I'm sure I could get the Bassani can looking good but I think the polished aluminum look of the Supertrapp will look better as well...Of course the are different diameters (Bassani header outlet 3", Supertrapp can inlet 2.5") but that will be easy to deal with.
    PXL_20211016_174732409.jpg

    Also started working on the wiring but nothing exciting to see. Got the taillight and rear blinkers soldered up with some resistors for the LED signals. Started looking at all wiring up at the controls....that is going to take some work. I have a good wiring diagram but it's still not straight forward as all I have to go on is wiring colors and relative locations, nothing labeled. It will surely be doable but will take time.
    #56
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  17. motocopter

    motocopter Long timer

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    Getting there @HuckIt!

    Are those "printed" fork caps plastic? If so, are you concerned the threads might fail?
    #57
  18. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    I believe there is a separate insert for seating the springs (part 44029 in diagram). These are simply decorative at this point—or at least virtually unstressed—since the handlebar clamps have been relocated. My Suzuki has similar rubber plugs in that location; they're just there to keep water and crud from puddling in the fork tops.

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    #58
  19. HuckIt

    HuckIt Been here awhile

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    Yep, that's right - thanks for the diagram, I was going to sketch something tonight to try and explain it but you beat me to it. The cap bears no load, just for dust and crud as you described. Just didn't want this look after relocating the clip-ons under the bars.
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    #59
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  20. motocopter

    motocopter Long timer

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    Still looks like the plastic cap is retaining the fork spring. The plastic cap is shown in the left fork tube, right?
    #60