Old School: <-2004 1985 Kawasaki GPZ 550 build thread - Kawasaki ZX-10R.net
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post #1 of 29 Old 12-09-2017, 02:02 PM Thread Starter
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1985 Kawasaki GPZ 550 build thread

So Iíve always been interested in building a cafe racer. Some of you may have seen my thread earlier this week and here was the outcome:



Sheís in my backyard now and Iím just about to start getting her together to see if the engine runs. Gonna take the tank off to get a good look, order the necessary parts as they come up.

Thought Iíd start a build thread to keep me honest (hope no one minds).



Ok.... here it goes!!


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post #2 of 29 Old 12-09-2017, 03:03 PM Thread Starter
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And if anyone can help a brother find a repair manual for this thing it would be greatly appreciated!!! Currently looking through google.


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post #3 of 29 Old 12-09-2017, 06:23 PM
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Subscribed. This is gonna be good.

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post #4 of 29 Old 12-09-2017, 08:48 PM Thread Starter
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1985 Kawasaki GPZ 550 build thread

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Subscribed. This is gonna be good.


This is gonna take a while! Hhaha.

The frame needs a lot of attention, Iím gonna have to cut the previous welds, grind them down and re-weld it. It looks like they just stacked welds on one another to get the gaps to close.

Ordered some things today just to get it going:

-clutch lever and perch
-left hand controls
-stator
-clutch kit

Once I get her breathing again, Iíll break it all down and focus on getting the frame right


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Last edited by Helitech; 12-09-2017 at 10:18 PM.
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post #5 of 29 Old 12-11-2017, 04:44 AM
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This is gonna take a while! Hhaha.
Its all good. If I were close by I would be glad to give you a hand with her. Looks like a project that will be as fun and rewarding to build as it is to ride when your done.
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post #6 of 29 Old 12-11-2017, 07:52 PM Thread Starter
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Looks like Iíve sourced someone a couple hours away that light have every single part I need. If thatís the case, this might be purring sooner than expected.


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post #7 of 29 Old 12-12-2017, 04:49 AM
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Couple of repair manuals on ebay if your interested.

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post #8 of 29 Old 12-12-2017, 03:55 PM Thread Starter
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So, quick change of plans. Gonna update this bad boy while Iím at it. Trying to source swing arm, and full front from a K6/K7 gsxr. This should be fun.....


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post #9 of 29 Old 12-13-2017, 10:18 PM Thread Starter
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Picking up a donor Zephyr to Frankenstein the engine for the GPZ.

The Zephyrís motor failed a compression test, so Iím taking all the accessories and wiring off to complete the GPZ. It also has a 4 to 1 exhaust with a hideous muffler, but thatís easily fixable.

The frame and suspension from the donor will go to a good friend of mine so he could start up a project.

Got all ball bearings identified depending on what GSXR front end I can source first. Will need to find a machinist nearby to make me some spacers for the swing arm. Not a gang of he three blade wheels on gsxrís, but getting some custom wires will be out of my price range and Iíd like her to at least have a 180 on the rear.




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post #10 of 29 Old 12-14-2017, 07:44 PM
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Do you jay leno motorcycles? Where's the value?
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