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TOPIC: GPZ550 Cable Lengths (Clip-ons)

GPZ550 Cable Lengths (Clip-ons) 07 Nov 2019 06:32 #813667

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Hey Lou,
possible to get pics of your clip on set-up? haven't received the set screw yet, but curious as to how much clearance is taken away using the shaft collar.

Here's a general location I was looking to put my clip ons . ( I know it's quite the turn radius sacrifice)
1981 Kawasaki GPZ550 (KZ550D-1)
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GPZ550 Cable Lengths (Clip-ons) 07 Nov 2019 06:38 #813668

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That is a lot of pull back. Have you ridden with bars set up like that before? My wrists would be hating that, especially on the throttle side.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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GPZ550 Cable Lengths (Clip-ons) 07 Nov 2019 06:47 #813671

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I have had some pretty deep clip-ons on an sr400 before, but not and this angle.

Really like the way it looks, so i was gonna give it a shot, and if I dont like it i can always change it.

plus these clipons have a little bit of a rise to them, so i figured the angle wouldnt matter too much as long as im not putting too much weight onto my wrists.
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 07 Nov 2019 08:34 #813673

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That does look pulled back too far. I think it would hit the tank at that angle.

My buddy has the same clipon setup as me, and his blog gives a good Idea of the clearance you can expect.

kz550a.blogspot.com/search?updated-max=2...tart=7&by-date=false

I took some photos of my red bike, but it's hard to get a sense of the angles when the camera is that close. It would be better to take photos from far away and then zoom it in.



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GPZ550 Cable Lengths (Clip-ons) 07 Nov 2019 08:59 #813674

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if you don't want to weld to the frame you can bolt bushings to the triple tree. I did it on my 86 GSXR that had the factory stops broken off. works good, might work on your GPZ

Attachment IMG_1372.jpg not found

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GPZ550 Cable Lengths (Clip-ons) 07 Nov 2019 09:42 #813675

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Hmmm, I guess i won't be able to tell how much clearance I need exactly until the shaft collar comes.

Happen to know if shaft collars come in thicker sizes that would provide me less clearance? kinda like a fender washer?
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 07 Nov 2019 09:59 #813677

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The spec on a 5/8" shaft collar is pretty consistent. I checked your link before you ordered and it was the correct thickness. The OD is 1-1/8" which is what you want.

The 550 stops are underneath the triple clamp, so it's not easy working under there, and the clamp stops are not round pegs, they are sorta like curved fingers. It would be tough to drill and tap a removable appendage there. You could maybe drill through the main frame peg/stop to make a removable stop.

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GPZ550 Cable Lengths (Clip-ons) 08 Nov 2019 07:14 #813710

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In case the shaft collar doesn't work, the Japanese custom scene atm uses something similar that I could use.
also a set that torques right onto the curved armatures.

runs about $30 but at that point it would be worth it
1981 Kawasaki GPZ550 (KZ550D-1)
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GPZ550 Cable Lengths (Clip-ons) 12 Nov 2019 19:25 #813927

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Hey Lou,

Just got the shaft collars in the mail, put it on and put it all the way to lock and it looks like my clip-ons will still be able to be at the angle I want with minimal compromise.
I'll put them on this weekend and update with pics.

Also, I have found some short Z1 clutch/ throttle cables in the japanese market. Your custom cables run 1184.3mm - 1190.6mm. These short cables say they run 10cm shorter than stock. so from the stock z1 cable (i think its 1282.7mm) will put the short z1 cable at 1182.7mm!

do you think the 1.6mm difference wouldnt fit well when my clip-ons have a raise to them? might have to lower them..., till then I can just run the looped stock cables.

very excited.

Thanks again
1981 Kawasaki GPZ550 (KZ550D-1)

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GPZ550 Cable Lengths (Clip-ons) 13 Nov 2019 07:24 #813941

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Is the free length the same? If the free length is shorter by 1.6mm you can probably still get it to work without much trouble.

If the cable housing's effective length is longer, and thus the cable free length is shorter significantly, you will probably have to modify something to get it to work.

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GPZ550 Cable Lengths (Clip-ons) 16 Nov 2019 15:05 #814067

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Howdy!

Got it done today, and I have to say... very pleased. Clutch nor throttle cables look weird but also work smoothly.

did not have to change brake line position either, which saved me a lot of trouble.
Had the clutch cable completely off because I originally was hoping stock routing would work. but unfortunately did not and I ended up adjusting the ball bearing plate way too far and had to put it back together ( thanks to the clutch adj resource on your page lou.)

Had a lot of fun putting it together, but got brutal once the sun started beating on me.

Only issue with my clutch routing now is not that big a deal but when steered all the way left that cable tightens up making it slightly harder to pull. pics below (excuse me gross looking headers...)

Took it for a ride to get the clutch adjusted the way I want it, and man I felt soooo cool.


I'd like to thank everyone who pitched their opinions in here and helped me out. I'm very grateful for this forum.
You'll be seeing me in the later on a different thread for a 4 into 1 exhaust jetting ;)
1981 Kawasaki GPZ550 (KZ550D-1)

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Last edit: by Caleator.

GPZ550 Cable Lengths (Clip-ons) 16 Nov 2019 16:14 #814071

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Thanks for the update! Glad it worked out. B)
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