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Time to rebuild my old GPz

Work in Progress

Moderators: chrisu, paul doran, Taffus, KeithZ1R

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Crofty
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Re: Time to rebuild my old GPz

#46 PostAuthor: Crofty » Tue Jun 02, 2020 8:16 pm

Top job.

Gyesdad
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Re: Time to rebuild my old GPz

#47 PostAuthor: Gyesdad » Thu Jun 04, 2020 9:30 pm

Good to see you're back on track with it. The painted motor looks very nice, can't wait to see the rest of it.


Gary.

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GPZ592
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Location: Surrey/Sussex Border

Re: Time to rebuild my old GPz

#48 PostAuthor: GPZ592 » Fri Jun 12, 2020 7:09 pm

Over the last week, I've started stripping down some of the GPz components to see what needs to be refurbished and/or renewed and I started with the forks & wheels.

The forks came apart without too much drama and once stripped and checked the stanchions have gone away for re-chroming. I had already upgraded to progressive fork springs from WP, back in the day, so they will go back in and I'm going to convert the forks to run cartridge emulators from YSS. These only have a single shim stack that controls both rebound & compression (unlike the more expensive Racetech units which have individual ones), but I think they will still be an improvement over the original system.

one fork stripped - one to go !

Fork Small.jpg
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YSS emulators

YSS emulator.jpg
YSS emulator.jpg (207.49 KiB) Viewed 249 times


The wheels were next to come apart as they need repainting and the discs were scrap. I was worried the disc bolts would be seized and if I used my impact driver gun, it would round the heads. So out came my trusty impact driver and 4lb hammer and they all came out without drama. I have a new found respect for the humble impact driver :D The bearings on the front wheel were a real mare to get out as I couldn't get the spacer tube between them, over enough to get a solid punch on the opposite bearing. Eventually after an hour or more and much swearing, cursing and the obligatory spilling of blood, they came out. In contrast the rear bearings took 5 minutes ! The spacer is just a tube with a collar pushed on and the collar on the front one had come loose, which might explain all the hassle I had. A quick tap with the hammer and it is back in place :)

Spacer before and after -

Spacer 1 small.jpg
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Spacer 2 small.jpg
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I gave the wheels a quick clean up and gave a section of the rim a polish to see how they would come up after languishing in my shed for 20 odd years and thankfully the rims look OK, but might need a bit of a deeper polish to take out any remaining imperfections.

Wheels before and after

Front Wheel small.jpg
Front Wheel small.jpg (64.9 KiB) Viewed 249 times


Wheels small.jpg
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Rim partly polished

Rim small.jpg
Rim small.jpg (48.06 KiB) Viewed 249 times


Mark.
"Racing is life. Anything before or after is just waiting" - Steve McQueen

Philippe
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Re: Time to rebuild my old GPz

#49 PostAuthor: Philippe » Sat Jun 13, 2020 4:08 pm

Hi Mark
you did a very nice job there! They shine like new. If you want them to stay that way give them a coat of clear coat. Degrease them with aceton and use a special clear coat for alloys, not a common clear coat. If you use a common clear coat they will start to oxidize underneath!
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

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GPZ592
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Re: Time to rebuild my old GPz

#50 PostAuthor: GPZ592 » Sun Jun 28, 2020 9:11 pm

Happy to report more progress being made !

I've had to have some remedial work done to the frame - the steering lock stop had to be re-instated on the headstock ( It had been removed to accomodate the "other" forks & yokes I was going to use). Also, the main stand bracket had gone oval where the pivot goes, so needed building up with metal. The original stand pivot tube had almost worn through where it was turning in the frame. Thankfully, i tracked down a NOS item in the USA as it's NLA via Kawasaki.

Additionally, the front mudguard had some rot between the brace and the guard itself and that's been cut out, with a new piece welded in. Thankfully, other than that it's sound and with some making good of the welded area it'll be good to re-use.

Built up and back to round !

Stand Bracket Small.jpg
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New pivot against old worn one - can you work out which is which :D

Stand Pivot Small.jpg
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Corroded metal removed

Rusty Mudguard Small.jpg
Rusty Mudguard Small.jpg (101.86 KiB) Viewed 151 times


Patched and ready to be finished

Muguard Small.jpg
Muguard Small.jpg (51.48 KiB) Viewed 151 times


Mark.
"Racing is life. Anything before or after is just waiting" - Steve McQueen

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GPZ592
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Re: Time to rebuild my old GPz

#51 PostAuthor: GPZ592 » Sat Jul 11, 2020 6:17 pm

Sometimes rebuilding a bike, you strike it lucky.

This arrived a couple a days ago - possibly the last NOS GPz550 ignition cover in the UK. It had been gathering dust dust on a shelf in a Kawasaki dealers for almost 40 years, until I tracked it down and liberated it :D

Ignition cover small.jpg
Ignition cover small.jpg (59.16 KiB) Viewed 67 times
"Racing is life. Anything before or after is just waiting" - Steve McQueen

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chrisNI
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Re: Time to rebuild my old GPz

#52 PostAuthor: chrisNI » Mon Jul 13, 2020 12:56 pm

GPZ592 wrote:Sometimes rebuilding a bike, you strike it lucky.

This arrived a couple a days ago - possibly the last NOS GPz550 ignition cover in the UK. It had been gathering dust dust on a shelf in a Kawasaki dealers for almost 40 years, until I tracked it down and liberated it :D



Doesn't happen often... :shock: :D :D :D


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