81 kz550. first time builder

[wargo522]

So i'm starting with an kz550 ltd that pretty much just needs to be cleaned up. this is going to be a slow build considering where i'm working on it is actually 20 minutes away from where i live. also i'm just only going to make it legal, safe, fun, and decent looking so i'm able to ride over the summer. come next fall i'll be stripping it completely then polishing and painting everything.

i've got a gpz tank coming to me since the ltd tank is retarded but i'm going to cut it and see what it looks like as the seat cowl

the bars going to be replaced with clipons or superbike bars. i have to find a set of blinkers to go on either side of the headlight. The instrument panel is moving to sit directly ontop of the triptree.

i'm going to X this setup and find a cheap some rearsets

motor is clean except this bit

this caliber and rotor are going bye bye infavor of dual disc setup off a kz750 that i have on the way to me

rear drum is being replaced with disc setup from kz750

new shocks on the way

cut the tabs off and about 4 inchs of the frame

not completely sure what i want with the tail
open to ideas you guys throw at me. you all probably know a lot more then me

 

[haplo_84]

gah i feel your pain man, mine is like 30mins away. I'm hoping i'll get a start on mine soon but school and work aren't affording me much time right at the moment. I have my clymers manual on the way and getting ready to order the carb rebuild kit soon. Like you i just wanna get mine running and ridable first before i do any real work to it.

 

[kookie31]

whew you got some work ahead of ya. no its not that bad. interested in what your future plans are?

 

[wargo522]

First off I need to buy some equipment: harborfreight 110 amp mig us number 1 on the list. Or unless I find a better craftsman or Lincoln mig on craigslist for around 200. But the necessary parts for the bike right now bars, seat, brakes suspension and lights. I'm actually driving down to fl today and will be stopping by dimecity to see what they it in stock

 

[Dale]

i've got a gpz tank coming to me since the ltd tank is retarded but i'm going to cut it and see what it looks like as the seat cowl

hey wargo522, personally I wouldn't go and cut that tank just as an experiment, unless its totally trashed. Hard to tell from the pics, but it doesn't look too bad.

• Obviously this is a matter of personal taste, but the more curvy tank may actually look better in a Cafe context once you've got rid of those ape hangers! The GPZ tank is a much more angular tank.
  
  How about rather using a cheap second hand bicycle helmet as a base to start off with your seat cowl? That way you don't destroy a perfectly good tank!
  
  
  
  
  
  
  
  
  
• Having said that about the GPZ tank, I had this in my archives, not sure where I got it from, but this looks to me like an 82-83 GPZ550 if I'm not mistaken. Quite successfully done I think, and may be some inspiration for your build? Who knows, maybe its even someone on this forum?
  
  
  
  
  
  Just my 5c worth. Dale
  
  
  

 

[wargo522]

That is hot. I'd have sex with it. As for the ltd tank Im not a fan cause it's to fat and makes it look like a sportster. The gpz tank I'm got is off an 81 so it doesn't have that angle on the crotch side. But thanks for the helmet idea that would perfect then I could sell the ltd tank

 

[wargo522]

got a bunch of my parts in today. rear caliber and master cylinder, swingarm, tank, front calibers and front wheel. also bought fiberglass, cloth, mat and foam to build a seat. should be building it this week

 

[Reinhard]

Checkout my build thread for a quick and easy way to make a cowl from the original tank, or any other for that matter, without destroying anything;
http://www.dotheton.com/forum/index.php?topic=20410.0

Welcome to the mayhem

 

[wargo522]

thanks bro. i wish my frame was flat to make it easier but i like the way the slant looks.

i only had 30 minutes today to measure and start laying foam so i'll have to get back with some more updates and pics on wednesday or thursday.

i'm trying to find a rearset solution but can't find anything cheap. so for right now i flipped the shifter 180 degrees and don't know what to do with the brake pedal. any suggestions?

 

[richa610]

Noticed you said something about a welder above. I recently got a Hobart Handler 140. I know its more expensive than what you have picked out, but it is sweet.

 

[mushroom_toy]

Stock tanks look best imho. Keep the carbs, run filters...but always keep some starting fluid handy. The jetting is super finicky. Keep the stock peg brackets, just run the rearsets on em. One thing to look for is to prob get a manual timing chain tensioner or make sure your automatic one works good - mine worked fine until about 20k, then started causing some probs. . oh and I wouldnt even bother with the double front disc, itll stop plenty good enough with single. Double on that bike might get ya killed. I had a 82 550, now i have a 82 750 and braking is comparable with weight.

 

[haplo_84]

There is a guy on here that makes nice looking rearsets. I'm actually planning on getting a set from him for my build soon. I'm still in the process of getting parts together though.

But heres the link to the thread. http://www.dotheton.com/forum/index.php?topic=22119.msg232901#msg232901

 

[Nebr_Rex]

Watch the length when you swap forks.
Get a manual,it will help a lot.
And check out KZRider.com .

 

[wargo522]

I'm not swapping forks because the stock forks on the 550ltd are the same on 750. The dual front disc is a bolt on I just need a dual disc wheel, which I have sitting in my garage. I just got my manual in the mail yesterday. Haven't really looked at it yet. Should probably take it to the bar with me tonight.

 

[wargo522]

Re: 81 kz550. first time builder aka Barney

Started on my seat.

Going to be shaving it some more tomorrow. May end up ditching it all together an go a different route.

The tank needs some bondo and I'll be priming it soon

 

[Dale]

That's looking sweet! How far back is the seat going to go? Are you cutting the frame at all?

 

[treitz]

I like the tank. Lookin good.

 

[Dale]

I like the tank. Lookin good.

Yeah, I wasn't convinced at first about swapping it out for the stock tank, but it looks like you've got your plan going, and you're sticking to it and its working for sure. Good for you man.
Down to the metal!

 

[cdiver666]

Looks good. I recently started my 80 kz650, so I'll be watching this one.
As for rear sets I've heard that 2004 GSXR 600 rear sets work on the kz650, so I don't know about the 550.
For the welder, I got a Craftsman arc welder for Christmas ($150) and it works pretty well but it burns through metal like crazy, so you're probably on the right track shooting for a mig. If you get the harbor freight, let us know how it works out. I might switch over.

 

[wargo522]

i ended up scrapping that tail and cut the subframe about 3 inchs. it was too long so i'll be starting over with that but it will be the same kinda of idea. just alot more refined and perfected. i should have some some more pics posted thursday.