DO THE TON

Turn your Brain Off and Shoot the Shit => The Collections => Street Fighters => Topic started by: Walda on Dec 16, 2012, 11:33:00

Title: Zephyr 550 build
Post by: Walda on Dec 16, 2012, 11:33:00
Hi, here are some pictures from my start rebuilding. base is kawasaki zephyr 550, 1991.
Title: Re: Zephyr 550 build
Post by: Walda on Dec 16, 2012, 11:36:15
progress and a bit of photoshop
Title: Re: Zephyr 550 build
Post by: two-smoker on Dec 16, 2012, 12:36:22
Y'know, the Zephyr is a bike I am pretty happy with leaving stock, but I do like the exhaust. In fact, i'm doing pretty much the same thing on my build. Did you wrap the tank in a motorcycle jacket? That's pretty unique-looking.
Title: Re: Zephyr 550 build
Post by: Walda on Dec 16, 2012, 13:07:31
I agree, the Zephyr series looks great, but I want it a little at my :)
Title: Re: Zephyr 550 build
Post by: jaddy10 on Jan 14, 2013, 01:39:01
Hey! a zephyr! you dont see too many zephyrs. I built my 1990 zephyr 550 into a fighter last year a lot of custom work and parts from other bikes. heres a quick pic.
(http://i77.photobucket.com/albums/j62/bboyer10/Zephyr/DSC01341.jpg)
Title: Re: Zephyr 550 build
Post by: Walda on Jan 15, 2013, 11:31:43
Great work man!!  :o Please give me more information about this Zephyr, thank you  :)
Title: Re: Zephyr 550 build
Post by: jaddy10 on Jan 15, 2013, 16:23:29
Great work man!!  :o Please give me more information about this Zephyr, thank you  :)

Thanks! the zephyr has been great to me last season. I finished the build march last year after working all summer fall and winter on it. Started out just a stock rebuild because the valves were getting really noisy. So I just decided to do a motor and carb rebuild. but in the process of rebuilding I ran across a 1999 zx6r on the craigs for a really good deal so I bought it and then it was months of figuring out how to fuse the front and rear end together.
from the front I milled the zx6r stem to fit the zephyr bearings then mounted a 2000 ducati monster front fender. headlight fork brackets for the stock zephyr headlight. fitted an acewell digital speedo/ tach rewired for the zx6r controls. I changed the tank and rear fairing to a 1998 zephyr 750, jetted carbs to 122 with UNI pod filters. 5/8 offset sprocket.

now for the zx6r swingarm to fit I had to cut the whole middle section of the frame where the pivots are and widened them about .5 wider. it was a task but worked out well. just make sure they are centered and level with the rest of the bike. I welded in a custom upper mount under the seat for the monoshock and welded in lower brackets for the shock linkages. then recovered the seat and fitted a 2004 triumph triple led tail light. It was a lot of work but it worked out great. I get a lot of questions where I go what kind of bike it is. ive only had one person actually ask if it was a zephyr. keep up the build man ive mashed on my zephyr all year and never gave me issues and with the suspension I am able to have more fun in the twisties. heres some more pics.
(http://i77.photobucket.com/albums/j62/bboyer10/IMG_1238_zpse1b0ee0d.jpg)
(http://i77.photobucket.com/albums/j62/bboyer10/IMG_1704_zpsd3bc7096.jpg)
(http://i77.photobucket.com/albums/j62/bboyer10/IMG_1236_zps21950cbf.jpg)
Title: Re: Zephyr 550 build
Post by: Walda on Jan 15, 2013, 16:36:21
Thank you very much for the information! Perfect rebuilding  :)
Title: Re: Zephyr 550 build
Post by: sphynx88 on Jan 18, 2013, 18:37:01
Was that pic from Backfire Moto?
Title: Re: Zephyr 550 build
Post by: jaddy10 on Jan 20, 2013, 01:52:05
Was that pic from Backfire Moto?

Yup I believe the July 2011 meet
Title: Re: Zephyr 550 build
Post by: sidejam on Feb 27, 2013, 00:26:33
Here's a pic of my 550 Zephyr. I think it falls somewhere between a cafe/fighter/bobber...

(http://i2.photobucket.com/albums/y6/sidejam/146.jpg)
Title: Re: Zephyr 550 build
Post by: Walda on Feb 27, 2013, 15:36:40
Nice machine, I looked at him :). How do you ride with the handlebars? Where did you get them? If I may ask :)
Title: Re: Zephyr 550 build
Post by: Walda on Feb 27, 2013, 15:45:46
Little Update
Title: Re: Zephyr 550 build
Post by: sidejam on Mar 02, 2013, 20:04:20
Nice machine, I looked at him :). How do you ride with the handlebars? Where did you get them? If I may ask :)

Here's another shot of the clip-ons:

(http://i2.photobucket.com/albums/y6/sidejam/IMG_1121.jpg)

For me, riding it is easy. It's a small bike and I'm 6 feet tall so it doesn't feel like that far of a reach. The bars are 41mm Woodcraft clip-ons with a custom spacer made to bring them down to the 39mm forks. Instead of using the aluminum bars that came with them, I cut up a pair of flat drag bars that had a 15 degree pullback. This makes the bars angle down even slightly lower and also helps them clear the tank. It took a lot of adjustments, but the bars are mounted symmetrically and will turn lock to lock without hitting the tank.

You have a great build yourself! I really like the way your tail section is coming along! While I didn't use the seat pan or foam, I used the exact same Ducati seat skin you've used to recover my seat after I cut it down.  Keep up the good work!
Title: Re: Zephyr 550 build
Post by: Walda on Mar 03, 2013, 04:02:01
Thanks so much for all the information! :) With the modifications I have to hurry, the season is approaching very quickly :)
Title: Re: Zephyr 550 build
Post by: Walda on Mar 03, 2013, 16:01:20
short muffler
Title: Re: Zephyr 550 build
Post by: Walda on Mar 14, 2013, 08:22:12
new side covers
Title: Re: Zephyr 550 build
Post by: Walda on Mar 26, 2013, 14:21:32
little creativity :)
Title: Re: Zephyr 550 build
Post by: Walda on Apr 16, 2013, 11:17:43
left-tune a few details, but otherwise done :)
Title: Re: Zephyr 550 build
Post by: thebronze on Apr 18, 2013, 11:13:46
I like 8)
Title: Re: Zephyr 550 build
Post by: Walda on Sep 23, 2014, 12:37:00
New fresh look :)
Title: Re: Zephyr 550 build
Post by: Drewski on Sep 23, 2014, 22:16:08
Really nice!! Bravo Sir!  8)
Title: Re: Zephyr 550 build
Post by: HerrDeacon on Sep 23, 2014, 22:19:57
Great looking bike. I really like the frame colour, goes perfect with the red.
Title: Re: Zephyr 550 build
Post by: AMD500 on Jul 18, 2015, 14:35:06
this bike is killer!
Title: Re: Zephyr 550 build
Post by: Raleigh550 on Dec 15, 2015, 14:45:56
New to the whole bike thing, but here is my 1990 550 Kawasaki Zephyr. have some plans to personalize