1981 GPZ 550 - It's something...

So, in December last year I purchased a shoddy looking '81 GPZ550. I originally thought I was in over my head since I have only worked with cars mostly in the past, but felt like now was the time to maybe go from four wheels to two.

I basically started stripping at the start of Jan 2015. It took me about a month to get everything labeled, photographed, and stored correctly on a shelf that was divided into all the various sub-systems of the bike. This really helped I must add, and as you clean, refurbish and assemble it really gives you a sense of accomplishment as the parts on your shelves get less and less.

As the only garage I could rent did not have an electricity supply, I became very well acquainted with my cordless drill, as well as an assortment of brushes, cloths, polishes, and rattlecan paint to help me get parts cleaned and looking as close to new again (IMO). I was also lucky enough to call in a few favours for getting parts bead blasted and primed.



To date I have completed the following (3 months of two hours of work, everyday after work):

1. Frame blasted, cadmium plated, primed, painted and clear coated.
2. Motor cleaned, paint stripped, repainted. (Next time I would definitely strip the motor completely and repaint separately.
3. Rims cleaned, sanded, painted and polished.
4. New head light and indicators and brackets.
5. Brakes have been refurbished and will be fitted (hopefully) this afternoon.
6. And various other tiny bits and pieces that took way too long to clean and procure (even cleaned all nuts and bolts by hand...never again)
7. And more.....

Not completely sure yet where I am going with this GPZ, but it definitely keeps my afternoons interesting.

Give it another 3 months, and I will be sure to upload a hopefully completed bike.

Looks good and it sounds like youre enjoying yourself.
Good luck with it.

So...the float needles are buggered. From Kawasaki South Africa I am looking at about $50 per needle and seat. Luckily I can get from Z1ent at $42 for a set of four, the catch though is because of our poor performing postal service I will have to pay an additional $80+ to have it shipped via a reputable courier/shipping company. How does Z1ent. products compare to OEM parts?

Grobbies wrote: How does Z1ent. products compare to OEM parts?

I think you'll have no complaint....Jeff Saunders (owner of Z1E) prides himself on supplying superior aftermarket replacement parts. And I sympathize about the RSA mail service...I have an friend in the RSA and it took the better part of a year for a package I sent him to actually reach him.

I'm getting £5 untracked from Uk to SA, maybe look for a UK supplier.

The twin shock GPz550 is my all time favourite, it is well worth restoring.

Was the rear frame rails chop your idea?

This is one I'm doing now:

This is how you don't spray a frame... needs to go higher



Basecoat before clear - I had to see what it looks like




Arty farty side profile pic:

Thanks McDroid. Think I will shop around a bit more...maybe I get lucky.

Tyrell Corp; The chopping of the frame was sort off a last minute mod after I saw this GPZ that was built-up by some garage, can't remember which one though. Your GPZ is really coming together well! Just fitted my front and rear calipers the other day. Finished sanding an polishing up the fuel filler cap, Didn't feel like repainting as the original coating on there was buggered rather bad. Don't know what they put on that thing, because paint stripper didn't make a dent in it. Also finished rebuilding the fuel tap. Now all I need to do is get the tank bead blasted or sanded (not yet sure) and then repaint or leave as bare metal (again....still not sure). Will post some pics when I made up my mind haha.

Oh, and Tyrell, if you know of a place in the UK that is not too bad and which you can recommend, please send me a PM.

Fuel filller caps are black chrome on the GPz, bright chrome on most other kz of that era. It is the same part from z400J up to z1300. The chrome is durable so they are not a difficult used part to find. The 'locks' are a 0000 cut, i.e. any kawsaki key will fit...in fact virtually any key.

Zed power UK are very good, I've just ordered one rebuild kit for my 750 from WEMOTO, my float valve is stuffed too. I'll report back if the pattern parts are any good.

Update: I was lucky enough to find some OEM float valve needles and seats for about $27 each in the RSA. WIll have the carbs on in the next few weeks. At the moment I am refurbishing the tank emblems.

Hi, looks like youve got the head and barrells off, Whats the reason for that? Those float valves and seats are a pain on this model. I know from experience I got a set of rebuild kits from somewhere in the states for a decent price. Put more photos up when you can.

@Chirpy: The heads stayed on. The motor wasn't taken apart since it was running rather well when I got the GPZ (despite the carbs being slightly out of sync)

The new float valves and needles are in, was going to fit the carbs today then I remembered loudhvx's (I think it was him) site about TK22 carbs. Had a look and thought I should just check out those tiny choke flaps first. Well, three of the four choke flaps had their pins half way out already. Seems like it was like that for a while since the pins, due to the movement, flattened the edges of the recess where the pin should go in (hope that makes sense) had to basically de-burr the edges and then slowly force the pin in. It worked pretty well. So thanks to Loudhvx I probably saved a bit of money.

Grobbies wrote: @Chirpy: The heads stayed on. The motor wasn't taken apart since it was running rather well when I got the GPZ (despite the carbs being slightly out of sync)

It sure looks like it is taken apart; are we talking about the same motor? Ed