25 years ago a housemate passed his test and bought a GPz550D1. He promptly crashed it and decided that biking wasnt for him. It sat around for a while but when he decided to get rid of it I bought it. At the time it was running but had bent bars and some other cosmetic damage.
The bike then trailled around with me for the next 20 odd years. I checked it still ran and kept it under cover but never got round to doing anything with it. Eventually I was desperate for cash so decided to sell. Usefully, so much time had passed that it had gone from being considered a cheap hack to a valuable classic.
A friend who had just passed his test was looking for a bike so, just out of courtesy, I told him that I was selling a GPz550. I said that it really wasn't the bike for him as it was a serious project and would take a lot of effort to turn into a useful bike. However; he jumped at it and took on the project.
The engine was running (badly) but the carbs were pissing petrol, the running gear was rusted everywhich way and the electrics were fubar. We decided, rather than refurbishing 40 year old tech, to replace the running gear with something more modern and to rebuild the carbs and lash up a new loom. I did all the mechanical work: fitting a GSF600 front end, ZR550 swingarm and ZZR600 rear wheel and brake. The rear shocks were specced to give the same steering geometry as a 2006 fireblade and, handily, gave the bike a much more muscular stance. The bike was delivered as a functioning machine but needing a serious amount of tidying up. The exhaust promptly turned to lace, the can went missing somewhere, the carbs continued to be a mobile fire risk and the loom was, ah, characterful. Also the engine was leaking oil from a previously un-noticed crack in the lower case.
This is how it was returned to me at the start of lockdown, last spring. The plan was for me to make a new loom, rebuild the engine, sort out the carbs and mount a new rectangular headlight with the original fairing. Yeah, leave me alone with a bike in need of attention and stuff gets done; new horn, cleaned up and repainted oil cooler, new bars, mudguard reversed to look more period, new exhaust sourced and fitted, carbs completely stripped and refurbished, engine vapour blasted and ceramic coated. I sourced a new rectangular headlight from Hella and designed a bracket which was then laser cut and bent to mount the headlight, relays, USB charger and fairing all in the right place. Getting the fairing and the headlight to look right together, and on the bike, was a labour of love on its own.
The engine was in pieces when I got it so it was rebuilt and fitted with ZX550 cams. The carbs were completely stripped and refurbished, float heights were way off and the constant petrol dribble cured by polishing the float tangs, allowing the float valves to close properly. The sump was on and off several times as threads constantly stripped and needed helicoiling. When the bike was finally started there was a serious oil leak from the sump so, after running the bike long enough to flush oil through the engine, the exhaust came off and the sump was dropped again. This allowed me to check for debris and to refit with a new, genuine gasket. The oil leak was cured but you can imagine my reaction when the sump plug then stripped. It was carefully tapped and helicoiled in-situ taking care to catch all the swarf.
So; here she is. There is a constant list of things to do; the carbs need vacuum balanced, the oil cooler isn't quite oil tight, but she starts easily, idles smoothly and, to my eyes, looks fantastic.