GPZ 550 Monoshock Build

duckdog28

New Member
Hey gang, been lurking for a while but first time poster. I'm finally getting around to posting my current project.
I've been working on a 1984 Kawasaki GPZ 550 mono shock build. This bike (see attachment - '82 CB900F - Rob Chappell) was my initial inspiration. I found others that were similar and I'll attach them later if there is interest.
 

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Re: GPZ 550 Build

But, I didnt have the cash to do an amazing bike like Robs and I didnt want to have to replace the whole swingarm/tire/suspension because of the cost and time required to do so. So, I started looking for bikes that already had a similar swingarm set up and found the GPZ550. Then, this bike became inspiration #2 (see attachment - '83 GPZ550 - Jeff Pochodowicz)
 

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Re: GPZ 550 Build

But, I wasnt in love with the original suspension, or the battery and electronics on the gpz so I photo-shopped my "ideal bike" and ended up with this (See attachment - ideal cafe bike) for what I wanted to try to build
 

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Re: GPZ 550 Build

So I started researching the GPZ and found that in 1984 the swingarm was changed to aluminum and got a little bigger, which I liked, but the tank changed and I didnt like it as much. So I started searching craigslist and found my bike. A 1984 GPZ 550 without a tank. It had been sitting and was last plated in 1997. I bought it for $700 bucks at took her home. Here she is on day one:
 

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Re: GPZ 550 Build

The bike would have looked like this in 1984

But I didnt like the tank so the next task was to find a tank from an '82 or '83 on ebay. I found one for about $120 and bought it.
 

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Re: GPZ 550 Build

So, with the new tank on it was time to get it running. With a little help, a carb rebuild, some new tires, and a new chain, I was able to ride her a few miles down the road;
 

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Re: GPZ 550 Build

I'm pretty mechanically inclined, but I dont have any fab. equipment, so I knew I'd need to find some help with welding some tubing. The guys in my area are chopper guys, but I was able to find someone cool enough to work on a cafe project.

Next, I bought a shock on craigslist. I found a Suzuki Bandit GSF1200s rear shock for $40 bucks. I talked with Rob Chappell about his build and understood that I might have to re-spring it once I got it fab'd in there. I also ordered a seat pan from Rob to match the one on his CB900. Now the bike was ready to go to the nearby fab shop. The electronics were gutted, the frame was chopped and I was able to get a look at what the new seat would look like. I decided that I'd need to trim the seat down a bit...
 

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Re: GPZ 550 Build

The guy who was helping me out with the fab work wasnt excited about my plans for the new shock. I dont know if he didnt like the idea of welding the aluminum, but he wanted to either build a new swingarm out of steel, or leave the factory suspension in place. He just wasnt excited about the way I wanted to do it, so no big deal, time to go and pick it up...
 

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Re: GPZ 550 Build

Now it was time to find another shop who could help with the installation of the Suzuki shock. Luckily I found a couple of guys from my home state of Indiana who had just opened a machine shop nearby. They were up for the challenge and had the shock installed with a pretty slick design in a couple of weeks
 

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Re: GPZ 550 Build

The guys said they could weld the shock mount to the swingarm but that the weld they'd do with the spool gun wouldnt look great, so it was off to find someone to TIG weld it for me. After a bit of a search, I was able to find a welder. Next it was time to get that dual exhaust off and get it ready for the old Bassani 4-in-1 pipe that I bought on ebay for it. I also removed the factory bars and put the new clip-ons in place. The controls are still dangling, so theres some work for later ...
 

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Re: GPZ 550 Build

Next it was time to tackle some electronics. Electricity is black magic to me, and I am lucky enough to have a buddy who is a ninja with such things. :D He was able to help me with extending the wiring harness and relocating the battery, fusebox, ignition and such;
 

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Re: GPZ 550 Build

Next steps will be to get the old gauges and idiot lights off of the triple tree and mounted lower between the forks and headlight. This will likely require a custom bracket so it'll go back to the machine shop in a week or two to see what they can dream up for me.

I also need to get the exhaust on but the studs are too long and not threaded far enough, so I'm trying to decide what to do about that...

Stay tuned, more to come in the next few weeks....
 
You going to do anything with that kink in the lower edge of the tank so the lines flow better into the seat?
 
I had thought about painting that bottom edge of the tank black, but we'll see...

Here are some better shots of the top mount when it was tack welded in place. It has been finish welded since these photos were taken:
 

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I'm with that Limey bastard (I'm one too ;D) on the tank. Trim the bottom to flow with the seat. I like your vision for the bike :) Is that shock from a linkage setup?
 
I'm working on the same bike, and modified the tank by cutting the walls out where your knees go, and then making steel plates to fit. I brazed the plates in place on the tank, and it turned out really sweet (in my opinion though).
 

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johnu said:
I'm with that Limey bastard (I'm one too ;D) on the tank. Trim the bottom to flow with the seat. I like your vision for the bike :) Is that shock from a linkage setup?

You Limey arsehole, I just snorted half a cup of PG Tips down my shirt laughing at that! ;D

I love the shock mount solution, very neat.
 
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