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New old KZ550 to be made roadworthy

  • Cwal
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  • 82 KZ550 C3 Ltd
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01 Oct 2020 12:09 #835978 by Cwal
Good day from coastal MA

My son (Member toast) recently acquired a KZ550 Ltd, C3 series. I'm helping him get it back on the road. It's been a while - my first bike was a 50s-era BSA Bantam, and my last was a Honda CB250 in the 70s. I'm a long-time tech writer doing manuals for computer and engineering/mobile robotics so somewhat familiar with mechanical stuff.

The bike seems pretty sound mechanically and runs well although reluctant to start. Takes a bit of coaxing. Found that water had leaked into the ignition because a stud is broken, the turn flashers were not DOT-compliant (replaced) and there is a lot of over-chrome paint that is flaking off.

We just replaced the front fork seals and they are leaking again, and now the front brake is kaput so I'm looking forward to learning how to put this stuff right and get the old bugger back on the road. The bike, not me.

1982 KZ550 C3 Ltd

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02 Oct 2020 05:52 #836016 by riturbo
Replied by riturbo on topic New old KZ550 to be made roadworthy
welcome.:) plenty of help here to get her sorted out .

Gpz 750 turbo The one I ride
Gpz 750 turbo Not finished
Gpz 750 turbo Not started
Gpz 550 1981
Gpz 550 1983
Bunch of other junk
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05 Oct 2020 09:37 #836212 by linuxrob
Replied by linuxrob on topic New old KZ550 to be made roadworthy
Found a lot of aftermarket fork seals leak. if the tubes are rust free and straight then get genuine OEM seals. Also stick with std or lower air pressure and do not overfill the forks with oil.

Regards and welcome
Ro b b

1980 Z500 B2 owned from new 78260 miles
1980 Z500 B2 in bits since 1982 23000 miles
2004 GSF1200S Bandit K4
2000 GS125 ESD
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  • Cwal
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  • 82 KZ550 C3 Ltd
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13 Oct 2020 13:48 #836791 by Cwal
Replied by Cwal on topic New old KZ550 to be made roadworthy
Thanks Linuxrob

(I also wrote Linux supercompute cluster manuals. This forum is a good "load sharing facility".)

We got the good seals from Z1, so I suspect we effed something up. The oil volume/level has different specs in several places.

1982 KZ550 C3 Ltd

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13 Oct 2020 19:10 #836824 by Nerdy
Replied by Nerdy on topic New old KZ550 to be made roadworthy

Cwal wrote: I'm looking forward to learning how to put this stuff right and get the old bugger back on the road. The bike, not me.



Well, why not you? :)

1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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  • hardrockminer
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14 Oct 2020 05:36 - 14 Oct 2020 05:38 #836844 by hardrockminer
Replied by hardrockminer on topic New old KZ550 to be made roadworthy
I really like the KZ550. The photo below is my wife's 1980 version. Mostly original except for the colour and a slightly modified seat.
The rear signals were moved to accommodate some small saddle bags. We picked it up a few years ago and rebuilt it over a winter. She has since purchased a DR 650 so this one doesn't get ridden very often. It's a bit too small for my 6 ft 3 in frame. I hope yours eventually returns to its former glory.


I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.
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Last edit: 14 Oct 2020 05:38 by hardrockminer.

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16 Oct 2020 09:06 #836989 by srsupertrap
Replied by srsupertrap on topic New old KZ550 to be made roadworthy
Not trying to create work but a good idea to check the charging system health too. KZ550 & UJMs charging systems in general are not robust. Dirty connections, loose grounds, overheated connections etc . often result in charging problems.

1981 KZ550 D1

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