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TOPIC: GPZ550 Cable Lengths (Clip-ons)

GPZ550 Cable Lengths (Clip-ons) 15 Oct 2019 16:02 #812526

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Howdy, new here so hopefully I don't cross any rules or anything.

I have a 1981 Kawasaki GPZ550 (KZ550). I plan on putting clip-ons (36mm) with a slight rise to them. Gonna have them set near the top of the triple clamp. So distance wise away from the stock bar its probably only 3.5-4 inches distance.

So the question is do you think stock cables would be good to use? Kinda just looking for opinions from people who have done clip-ons before on a kz550A or first year gpz.
Been having trouble finding good cable sizes.

Thanks in advance.
1981 Kawasaki GPZ550 (KZ550D-1)
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GPZ550 Cable Lengths (Clip-ons) 16 Oct 2019 05:18 #812539

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Stock GPz cables are probably going to be shorter than any other stock cables. But maybe check into KZ305 cables or some other smaller models. Z1Enterprises.com lists the cable lengths. Motion Pro & Barnett are a couple of places that make custom cables.

....

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GPZ550 Cable Lengths (Clip-ons) 16 Oct 2019 13:53 #812563

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Here's what you need:
gpzweb.s3-website-us-east-1.amazonaws.co...tchCableShorten.html

The stock cables will be usable but will be too long. The throttle cable gets routed forward so that loo will be bigger but won't really interfere too badly. The clutch cable is much more problematic. You will need to secure it pretty good and make sure the excess is looped smoothly. I loop it upward more than normal and then it loops smoothly to the lever. It should still function fine but will look "loopy". I've run it like that for years with no problem other than looks, but eventually got tired of it so I cut them to length.

The brake line will be way too long to get to the splitter. I delete the splitter and run a single line to the right caliper, then another line from right caliper to the left caliper.

I cut down the stock cables rather than use Motion Pro cables. The Motion Pro cables never feel as good as the factory ones.
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GPZ550 Cable Lengths (Clip-ons) 16 Oct 2019 16:09 #812565

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This is very in depth, thanks.

cutting the cable short look a little more in depth for me right now lol.

Would the brake line actually be too long to get to the splitter with how little I'm moving it? I don't mind changing the lines of necessarz but if that's the case where is the best place to get brake lines for those dimensions?

thanks again.
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 16 Oct 2019 16:36 #812567

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I think it can all be made to work without cutting any cables. I ran it like that for a little bit before I was certain I would keep the clip-ons. Everything will just have to be looped in a way to not kink.

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GPZ550 Cable Lengths (Clip-ons) 16 Oct 2019 16:37 #812568

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A much bigger problem is hitting the tank with the clip-ons. You will need to stop down the steering before you ever install the clip-ons or it's guaranteed to scratch or dent the tank.

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GPZ550 Cable Lengths (Clip-ons) 17 Oct 2019 05:27 #812582

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By Caleator: .... where is the best place to get brake lines for those dimensions?

Goodridge brake lines from Z1Enterprises.com come in various lengths & Z1Ent has goodridge banjo fittings w different angles. With Goodridge if you get the wrong length or change bars again in the future, swapping out a new brake line is a simple matter. I installed ss braided lines w clear pvc 6-7 years ago, then swapped them out just last week w black >> it was very simple. just unscrew the old lines & install new. I installed a Honda CBR500 master cylinder, so I had to swap the banjo fitting there. still pretty easy.
...
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GPZ550 Cable Lengths (Clip-ons) 17 Oct 2019 10:58 #812600

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has any one had any luck with mounting a narrower to the steering stopper?

ive done something like this before on an sr400, but that one had easy access mounting points. the gpz550 does not appear to have anything like that.

also ill look into those brake lines as well, thanks.
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 17 Oct 2019 11:44 #812604

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Caleator wrote:
has any one had any luck with mounting a narrower to the steering stopper?


Show us your steering stop we will show you the solution.

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GPZ550 Cable Lengths (Clip-ons) 17 Oct 2019 14:01 #812611

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Here it is
1981 Kawasaki GPZ550 (KZ550D-1)
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GPZ550 Cable Lengths (Clip-ons) 17 Oct 2019 16:14 #812620

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Try to put an alu/steel tube on the steering stop bolt.

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GPZ550 Cable Lengths (Clip-ons) 17 Oct 2019 21:27 #812627

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that's a good idea I'll give it a shot when I put on the clip ons eventually.

I'll update back here then I get them on at some point.

thanks again guys
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 18 Oct 2019 05:16 #812636

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You probably ought do the steering stop first to avoid any mishaps w the clip-ons. At the least you could try pvc tubing from the hardware store. As per scirocco's suggestion, I would install a metal sleeve over the steering stop & use a set screw to keep it in place. you'd have to drill & tap a hole for the set screw. use a thread locker on the threads.

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GPZ550 Cable Lengths (Clip-ons) 18 Oct 2019 05:37 #812639

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Maybe glue a piece of thick rubber hose over it. Not as permanent as metal, but might work just the same.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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GPZ550 Cable Lengths (Clip-ons) 18 Oct 2019 06:45 #812647

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Like Scirocco said, you want some kind of bushing on the stop pin to make it bigger.

I've done many. I strongly recommend getting it welded. Setscrews will hold it in place for welding, but will not hold it permanently. Vibration will make it fall off eventually. I've brazed one on before with oxy-acetylene. That worked ok but eventually came off in an accident... a very bad accident where the frame was totalled.

I see the paint looks good, so it will be more work to paint it after welding, but it's worth it.

Maybe there is a way to drill a hole all the way through the stop pin and just put a bolt through it for the yoke to hit. There is not much room to work up in there.

Also, once the steering is stopped down, you can use a wider range of steering dampers since the travel will be a more normal range. There is a lot involved with that since the oil-cooler is in the way, but at least you can start planning now that the travel is set.

The cut surface goes up against the frame.

Once it's in place you can sand it down just enough for the steering lock to still work.
You can also sand down the steering lock stop to make it still work.
There is plenty of play for the steering lock, so sometimes it might still work without doing anything.









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GPZ550 Cable Lengths (Clip-ons) 21 Oct 2019 12:23 #812824

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Lou, as he so often does, has offered the professional, permanent solution. I would put that at the top of my list.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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GPZ550 Cable Lengths (Clip-ons) 05 Nov 2019 10:27 #813585

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Hey lou,

thinking about doing the clip ons soon,

www.globalindustrial.com/product/itemKey/30263565

Will this shaft collar work for the stopper?

Hopefully my cheap rotary tool will be able to cut it
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 05 Nov 2019 12:28 #813592

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Yeah, the link says the OD is 1-1/8". That's about 28.5mm.

All it takes is a good hacksaw and 5 or 10 minutes with a steady hand. A file can clean it up easily.

You will want to take off the zinc plating in the welding areas, and remove paint from the end of the stop on the bike.

It might be better to find one in raw steel. It will weld nicer and you won't have to worry about the plating. Then just paint it with a brush to stop it from rusting.

This one would be better than the zinc plated one. It is difficult to see if all the zinc is off. This black oxide is much easier to see and I think may be less problematic for welding.
www.globalindustrial.com/p/motors/collar...rew-collar-gsc-062-b

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GPZ550 Cable Lengths (Clip-ons) 05 Nov 2019 12:48 #813596

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Thanks for the quick reply, canceled the order on the zinc plated ones, and ordered two of the other ones just in-case.

Might be a week or two before I get it and put them on, but i'll def be back to update on how it goes.

Thanks again.
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 05 Nov 2019 12:59 #813598

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If I remember, I will try to get better photos of the stop installed.
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