Well
Installed the flatslides, synched them. It started right up. The carbs feel right I think the jetting is dam close.
I rode it around the neighborhood, as I do not have lights on it yet.
It runs. Rode it around for ten or fifteen minutes. This is the first time I have actually ridden this thing since the project started. Feels really good. vibration is minimal, the bike pulls hard. It was awesome.

Then I blew a 15 amp fuse. Ok well we made a huge step forward today. I guess it is time to put lights on it and make sure there are no bare hot wires left over.

Weeeeeeeeeeeeeee !!

I wouldn't bother with frame bracing, the stock GPz750 frame is pretty stout. If you already have the 810 kit I would buy a full set of piston rings and have your cylinders bored and honed for the pistons. Can't comment on the 18" front tire I run stock 19". I have ridden my 82 GPZ750 track days very aggressively. It has the stock frame and is powered by a highly modded 82 GPZ1100 engine. It handles really well and the only changes I have made to the suspension is a ZRX swingarm and shocks and the front end off a n 82 GPz1100. The thing is ungodly fast and handles really well.

By beating the bolt throught he powder coating you probably flaked some of the coating off and shoved it into the swingarm bearings. I would remove the bolt then clean the bearings and the coating off the inside of the bolt holes.

When installing the swing arm back onto the frame after the frame being powdercoated the diameter of the bolt hole was smaller(due to the coating) i really had to BEAT the bolt through, could i be in for problems due to the bearings in the swing arm perhaps being damaged? should i remove it and buff excess coating off the inside on the hole?
also had the same with the top shock absorber stubs, i buffed the coating off and bingo, no problem going on.

Leason learnt now, any others i come across i will remove excess powdercoating
Im just worried about the bearings, but it seems to move freely enough, but should i bother removing again?

I believe I have it beat! I have an Aluminum GS1100 swingarm and a KZ550 mag wheel with drum brake. The swingarm has a 20mm axle so I got KZ1000 bearings. the only part not 20mm yet is the brake cover. I'm either going to drill the one I have to 20mm or see if a KZ 900-1000 cover fits the wheel

Not necessarily what needs to be done first, you need to do a bunch of things: change the oil and filter, squirt oil down the cylinders and turn the engine over with the kicker, slowly, a few times. Install new plugs, clean carbs, remove air filter and look for mouse nests, same with the exhaust. Lube cables. Unplug all the terminals, clean them and spray down with WD40 then use some dielectric grease. New battery (yes you need it to run properly) and you should be able to start it up. Iwouldn't even try running the bike without doing all those things thoroughly. It will save time later on if it's not running right, you can cross all that stuff off the list.

Anything after that is all chassis: tires, service suspension and swingarm pivot, etc.

Ok so it looks like i neglected this post for a while but here's what i've been up too. I couldn't stand the rust and faded frame paint. The engine was clean but tarnished.



Refinished the wheels




Redid the header/exhaust, painted the swing arm




Rebuilt the forks, Progressive brand fork springs and paint.



Painted the engine and triple tree.




Reassembly begins. New Progressive rear shocks mounted and battery tray cleaned up big time. Don't mind that rusty screw, it's gone now.




Here's how it sat after the winter, seat was temporary but it looked great,



With seat done



With new muffler




Complete list of modifications.

Superbike Bars / Oury Grips
Rebuilt forks with new Progressive fork springs, lowered internally 2-3"
Progressive Rear Shocks
Front Master Cylinder from a 96 ZX7
Ballistics 8cell Lithium Ion Battery
New Carb Holder, UNI Pod filter / Crank case Breather
Shinko 712 Front and Rear tire
RK 530 Chain, New Front and Rear Sprocket
Dyna Solid Core Spark Plug Wires/ New plugs
Dynojet Stage 3 Jet Kit
Detab/Smooth the frame, rear hoop, fresh paint on everything.
Cleaned or Replaced Front wheel bearing
Smaller blinkers from Dime City Cycles
Modified MAC 4-1 Exhaust
MOSFET Regulator/Rectifier from a 2008 CBR600RR
SS Bolt kit from Z1
Rebuilt Petcock
Rebuilt Starter clutch

I agree with Mcdroid. My KZ650-C1 has bushings, and they work perfectly fine. HOWEVER, if I had a bike with bearings I wouldn't retrofit bushings.

One thing I noticed in looking at the '82 GPz750 swing arm diagram is that the swing arm has no grease fitting. With bushings a grease fitting is an absolute must. In looking at the horrible condition of your pivot sleeve I wonder what happened. There are oil seals on each end that are suppose to protect the needle bearings, but judging by the wear and pitting on the sleeve it looks like any grease that was originally in there was long gone. Were the bearings dry when you took it apart? Maybe a previous owner got carried away using a pressure washer? Ed

If it was me, I'd replace the sleeve and axle and still use needle bearings, instead of retrofitting with bushings. As long as you don't treat the GPz as poorly as the previous owner, the needle bearings in that swing arm should last years without needing to be replaced.

:huh: Let's start at the beginning. Back in '96, I was given the remains of an '81 KZ650H. The CSR model. It was missing a piston and rod. I never did anything with it. Acquired a second KZ650, A "B" model with the famous 'duckbill' and rear drum brake, but a non runner as well and again was giving it a home. Some where along the way bought a KZ750 engine. Well, about 2-3 yrs ago made a trip to Phoenix to trade a GS 1000 for a '77 KZ650 with a rear disc brake which is what I wanted all along. Well the "B" had a title so I was going to swap swing arms and make some plate to mount the rear master cylinder for the brake (I don't have a welder) and make it all work. Interest waned, life got in the way or other priorities came about, what ever it's called the project stopped a few years. I broke down and and did what it took to get title for the rear disc brake frame. Swapped the swing arm back in and installed the original 650 engine in.
Well, as many of you know, looking in Craigslist can be evil. There was this '81 KZ750 engine listed. I've wanted a later case to build my idea of the ultimate KZ650 engine. You know, Hyvo cam chain, electronic ignition and 750 carbs and head. I went to see this engine and it had the factory oil cooler on it. The price was right so I got it. After a couple days thinking about it, I decided to just install this engine as is. Sure I got to make brackets for the oil cooler. That's part of making the bike "mine". I just finished a XS650 SG project a couple months back so I'm primed for this one. That and having these frames/engines kicking around here the last 20 yrs, it's about time I did something with them!
The bike sits now with the 750 engine with it's oil cooler hanging limp in it, Rear disc brake swing arm and wheel back in. I need to rebuild the carbs, install the starter, alternator and electronic ignition system to make the engine whole. More story and picture to follow later.