81 GPz550 / ELR

looking good mate.

was thinking of doing a kz550 myself for my wife,
i'd have to sell here seca 650 first though lol.
and put my z1000r together,oh and rebuild my dr650 motor:ohmy:

Cool, i like it man....great idea!

Made some minor progress this week:

- I got the appropriate steering stem bearings to fit the 1000P triples to the 550 frame. Now I can work on making the proper sized steering stops to keep the forks away from the tank.

- I was also able to get the right OEM Kaw rear axle to fit the 1000P rear wheel into the 550 spec swingarm. An '82 KZ750 axle is the perfect fit. ($8 incl shipping , Ebay) The 550 rear rotor bolts to the 1000 wheel, so that will make the brakes a bolt-on job. I still have to sort out the front axle, but I have something that will work with a minimum of fuss if I don't come up with something better. I'm waiting for dimension from a ZR750 axle. the ZR piece has recessed allen caps for fastening, which would be cleaner looking than my other option.

Over the weekend I intend to get the sawzall out and remove the rear shock mounts and the gusset that they are attached to, the blinker/bungee bosses, and any other unnecessary stuff. Fortunately, the 550 frames really don't have too much extraneous junk. I'd also like to get the bearings out of the wheels so I can get them off to the painter, now that I know that I will be able to mount them without altering them to fit.

Removed the old shock mounts and also the blinker mounts today. Before and after pics below.

After..

Got the shock mounts done today !! Original position was near where I have the "O" marked.

Bike is now on two wheels ! I got a Concours 1000 front axle, it was nearly a perfect fit, I had to turn down the end caps 1mm. Also got steering stem bearing that mate the front end successfully to the frame. Steering stops got built today also. A little detailing and the frame will be off to the powdercoaters !

Mike, Love your projest.

A good upgrade for that engine is the ZX550('84->) pistons and cams. The ZR550 Cams have the same profile as the '81-'83, but the ZX cams have a better profile, and stock the exhaust cam is advanced. I believe someone is selling engine internal parts on ebay right now.

Keep up the good work.

I will watch those pistons Corey, I might grab them. I was actually thinking of going the opposite direction with the cams, I have a set of KZ-A cams that I was considering putting in (ONLY if the valves are out of adjustment and I have to take it apart anyway). I like the added mid-range.

Speaking of the motor, this morning I unburied it from under the stack of boxes in the back corner of the garage. It had been patiently waiting there for 4 or 5 years. The case paint looks a lot better than I remember !!! Now I can just prep and paint, I won't have to strip like I thought I was going to have to. I'm hoping to get it painted black tomorrow.

I also dropped the frame off at the media blast shop for paint prep today, that should be done tomorrow.

Got motor painted today. I will do case covers separately, probably with gloss black Gun-Kote;

...and I got the frame back from blasting...

So I painted that too. i decided to skip the P/C and use the same 2 stage black that I use on the bottom end of the motor. Tomorrow I'll wet sand it if it needs it and put a finish coat on it

Soda blasted and painted the wheels today. Also put the motor in the frame while waiting for paint to dry.