Repairing/Restoring my 1981 GPz 550

So I got a few hours today and - overall - was pleasantly surprised with what I found.
I cleaned the mouse nest out of the airbox and washed it thoroughly.  I emptied over 2 gallons of 10 year old gas out of the tank.  No signs of rust but I will keep my eyes out anyway.  Glad my friend left so much in it!
The carbs were all surprisingly clean - I was expecting far worse. They all looked like below with just a light powdery film.  Gave them a good rinsing shower of carburetor cleaner.


Despite looking so bad - I am pleased that the brakes are cleaning up nicely.  The front master cylinder was actually ok - but I already have purchased the rebuild kit so I will go ahead and do that.  Thanks loudhvx for the link to the Ninja 250 rear master cylinder replacement!  I've been looking for a OEM replacement and will continue to, but I will probably go ahead and start the replacement with the Ninja unit as well. 
All of the pistons popped out easily with some air pressure and the seals were all actually in good shape. One of the boots (I think that is what you call them?) was torn a bit (below) but the rest were fine. I may replace them all anyway if I can easily find replacements - I haven't looked yet. 
I may be in agreement with Nerdy about the restoration - not sure, but you can see I definitely need to do some painting on the brake calipers as the black pain was bubbled and easily peeled off (any suggestions on a particular paint?). Definitely need to touch up some paint on a few spots on the frame as well.
I had that seat recovered back around 2005 as the original simply wore out and ripped along a seam.  I'd love to have it look more like the original cover.  If you have a lead on a more authentic cover - shoot me a link!




Have a great week everyone !
Paul
 

I’m having good lock with VHT caliper paint. After it air cures for a day, I heat cure it at 200 degrees first for 30 minutes and let cool. Then at 200 for 45. The paint flows nice. Not sure about durability yet. I used VHT chassis and roll bar paint to touch up the frame on my 1978 LTD 1000. You can’t see the touch up spots. Blends in perfectly. Both in satin black. 

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I had that seat recovered back around 2005 as the original simply wore out and ripped along a seam.  I'd love to have it look more like the original cover.  If you have a lead on a more authentic cover - shoot me a link!
 

Unfortunately I bought it a long time (12 years?) ago and finally installed it 4 years or so ago. The installation instructions might still be in the shop, though - I will look.

There is a seller on ebay called 'Pit Replica' or similar that has an OEM-looking seat cover for the '81 GPz550, but the Kawasaki lettering on the back panel appears to be done in gold or something, rather than white. Boo.

If I can get the seat out into the daylight and get a decent pic, I'll post it here.

Before I forget (again), what sort of exhaust is on there? It appears to be a 4-into-1 but we can't see the right side of the bike. No pressure.

Here's my tip for sourcing hard to find NOS parts on eBay. Look up the Kawasaki part number on Partzilla and do an automated daily search on that number. You would be surprised what comes up eventually. You just have to have patience. I've also had good luck with getting original hydraulics re-lined. Apple Hydraulics is one such place. 

Yes - when I bought it back in '86 it had a 4into1 on it but the previous (only) owner had also provided the original 2into1s - but not the needed mounting clamps and split collars.   I didn't like the 4into1 but I was too young and stupid to think about getting the needed replacement parts back then.  I am going to try to find them now though.



 

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Yes - when I bought it back in '86 it had a 4into1 on it but the previous (only) owner had also provided the original 2into1s - but not the needed mounting clamps and split collars.   I didn't like the 4into1 but I was too young and stupid to think about getting the needed replacement parts back then.  I am going to try to find them now though.
 

ThatGPzGuy nailed it: searching ebay for OEM part numbers works. I've found a lot of stuff that way, like NOS exhaust collars for the KZ440. Normally I start with Partzilla to look for items that are still available, and if they don't have what I want then the part numbers are right there.

Appreciate you posting the pic of the exhaust, btw. Whoever worked on my GPz550 installed a 4-into-1... and bent the heck out of the exhaust studs and the flanges on the pipe for each cylinder by tightening them far too much.

It looks like a long way to go before you can finish this build. The update seems neat, but you need to polish and replace more things. The motorcycle exhaust of this ride fell out of it.

Okay, I got a pic of the seat. And my memory is crap: I was grumbling about the gold-ish Kawasaki lettering on the Pit Replica seat cover, and mine doesn't have any lettering at all. D'oh!

 

I believe the OEM seat was heat-embossed but this one is stitched, which is kind of nice.

Also the original seat foam was trimmed a bit by a PO.

No eBay APP ID and/or Cert ID defined in Kunena configuration

Nice OEM replica seat cover...

Edit: for some reason the forum software won't accept ebay links anymore.  Search out the following...eBay item number: 152139877836

Direct from the manufactuer...eBay item number: 182800694410

No eBay APP ID and/or Cert ID defined in Kunena configuration

wrote:

Nice OEM replica seat cover...

Edit: for some reason the forum software won't accept ebay links anymore.  Search out the following...eBay item number: 152139877836

Direct from the manufactuer...eBay item number: 182800694410

Have you used one of these cover?  Is the quality good?  They list a ton of covers for KZs and they look good in the pictures.  

www.ebay.com/usr/pit-replica

I bought this one from Z1.
www.z1enterprises.com/seat-cover-kawasak...%2Fall-models%2F1981

The quality is superb, with accurate detail, almost indistinguishable from the original, in my opinion.
Nice thick vinyl, and it installed easily. 
You be the judge...

 

Sweet.  That does look like the original!