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KZ550 Project by Jramsey89 28 Jul 2011 01:17 #465448

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Well I have been working on this for a while (too long actually) and its about time I started a project thread.
I bought this KZ550A earlier this year as my second 550 (totaled the other one, using it for parts) It ran and shifted through all 6 so I gave 500 for it. I'll post up pics of what I have done and keep them coming as I progress. Any suggestions and info are welcome and thanks for looking!

This was taken the evening I bought it.
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JRAMSEY89 Project KZ550 28 Jul 2011 01:33 #465450

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This is the bike at my parent's garage in a little bit better light


Dis-assembly! I have all the body work off.
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JRAMSEY89 Project KZ550 28 Jul 2011 01:46 #465454

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Same thing from the other side. I also swapped out the clutch cable and chain cover from my other bike. It seemed easier to do both rather than just the cable.
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JRAMSEY89 Project KZ550 28 Jul 2011 01:49 #465456

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Delivery! New Kenda Challengers. Not the best but a good deal though.


I decided to go with a GPZ fairing so after searching ebay for a couple weeks I found a usable one for 50 bucks

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JRAMSEY89 Project KZ550 28 Jul 2011 01:59 #465457

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I moved the bike to my brothers shop. its closer and nicer to work in. thanks bro. I decided to mount and balance the tires myself... but i cheated and used the tire machine where i used to work.
Front tire is off!

Here's the new tire, mounted and being balanced. balancer is 50 bucks at harbor freight and works great
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JRAMSEY89 Project KZ550 28 Jul 2011 02:14 #465459

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Sorry for poor photo quality. I polished the front rim and got the tire back on. Back tire's off now. If you get to wondering,the bike in the background is my brothers kz1000 he just got and the exhaust on mine is an original kawasaki by kerker and is probably worth about as much as I gave for the bike.

Well its time for body work, which i am doing at my parent's garage since they have an air compressor. I started stripping the paint on the tank and fender. I am using the tank from my other bike which surprisingly only has one dent that needs major attention. The tank off the new one is okay but not as clean inside.
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JRAMSEY89 Project KZ550 28 Jul 2011 02:21 #465460

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Alright, after some sweat and burned skin the tank is stripped.

And here I have put on the first round of body filler.

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JRAMSEY89 Project KZ550 28 Jul 2011 02:25 #465461

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Just some cleaning minor stuff. Here is what the carbs looked like originally

And here I have them somewhere around halfway done

That was after 20 minutes on each side with a dremel. I put in another 20-30 per side that I need to take pictures of still.
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JRAMSEY89 Project KZ550 28 Jul 2011 02:38 #465462

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Back to the body work. I got the tank straight and into etch-prime. It looks green in one picture but its actually grey.


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JRAMSEY89 Project KZ550 28 Jul 2011 02:39 #465463

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I decided to keep the factory airbox after doing a lot of research and reading where people say pods are not the way to go (my other bike had them and I was neither for nor against them). I ordered new airbox to carb boots and I will say, putting them on almost made me want to switch to pods... I finally got them after about a half hour of pushing, pulling, twisting and stretching.

I also got the rear all set up with the new tire, chain, and sprockets. I had to bend the flat bar that keeps the drum from spinning to clear the larger 130 rear tire but it worked out fine.
So that's about where I am now. I will add more as soon as I get a chance to get some work done. Its really starting to come together. Thanks for looking!

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JRAMSEY89 Project KZ550 28 Jul 2011 09:58 #465494

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FYI if you have new boots try this when putting the carb rack back into the bike. Fold the boots over on themselves and fit them into the airbox. Then slide the carb rack into place. By folding the boors over you will gain about an inch of clearance and the carbs will easily fit into the front holders. Then all you have to do us unfold the boots over the back ends of the carbs which is very easy. ;) Family secret that has been passed down and I would not do it any other way. But you have to have new or soft boots to do it.
Take it from me cuz I found
If you leave it then somebody else is bound,
To find that treasure, that moment of pleasure,
When yours, it could have been.
1977 KZ650 B1 Being restored to original (Green)
1977 KZ650 B1 Original (Red) Sold
1977 KZ650 B1 Donor Bike for Parts

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JRAMSEY89 Project KZ550 28 Jul 2011 20:23 #465567

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thanks for the tip... if only I had known before haha.

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