Kawasaki GPZ500 Custom Cafe Racer Project

[MiniMan96]

Hey all. Im new to this so bare with me. Been pestered to join this for a year by Fladdem but I've been too busy to join... So why not do it at work while I have jack shit to do?


Anyways, around Mid September I bought a fully working GPZ550 off my mate (Fladdem) who got it for free. Instead of doing my A2 and riding that I thought "Hell with it. They look awesome cafe racer'd". So to his disgust I stripped it down over a few weekends in the shed and planned what I was going to do with it. My plans were to put a ZXR600 front and rear end on with Upsy Downies and a Ohlins shock from work. After searching eBay I didn't come across any parts within my price range, but I came across a VFR750 single sided swingarm. So I showed my step dad, as he was interested, and passed a comment of "Fuck. I wish I could but a single sided swingarm on mine" to which he responded "Why not? You can make anything fit". So me being me I accepted the challenge and bought the whole rear end (Braided brake line, calliper, disc, swingarm, showa shock, the linkage, CBR wheel with tyre and sprocket) for just £250 with postage.

The next job is to get that fitted (I ran out of time and money due to my shit pay package and busy work life style) so I'm still waiting to fit it to my frame. I've already cut out the rear sets and suspension linkages as they were going to be in the way, so I just need to find a tig welder and fabricate a new suspension mount and rear sets mounting position.

So while I was waiting for that I kept at the hunt for a front end. With no luck I found some Aprillia RSV Millie top and bottom yokes, so if any forks, callipers, wheel and disc's come along for a reasonable price I'll buy them. But in the meantime Im going to look at making the yokes fit as well as the swimgarm.

Thats all I've done so far as I really haven't had the time to work on it. But the possibility of even converting it to injection instead of carbs came to my head, but its probably too much money than its worth.

Im using a computer at work and don't have any photo's at the moment but ill upload some tonight, or Ill look at getting them off my phone and upload in the next hour.

Cheers Guys, Anthony.
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Classic Mini, Land Rover Defender 90, Kawasaki GPZ550 Custom (Bought from Fladdem), Honda VFR400 NC24, Suzuki GSXR400 gk73a

[ZX-7R]

Sounds an interesting project mate.Looking forward to seeing some pics.
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Current Bike - 2000 ZX-7R

[Matt B]

[Rogerborg]

Hi Anthony, welcome to BCF.

Do you actually intend to make a ridable bike, or is this more of an engineering exercise?

Is the sort of question that you're likely to be asked here.

[pulls up chair, awaits Pete, sickpup and stinkwheel]
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Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[andyscooter]

[MiniMan96]

Haha Yeah I don't want to disturb you with those photos.

Yeah it's more going to be a show bike, but its also going to be ridden often so Im going for reliable too. Im not doing any bodge jobs on this bike, I want it to be a one of a kind I guess but I do intend to ride it long distance as well as show it off with my car.

Im currently in the process of uploading the photos off my phone onto the computer but the wifi is terrible and its taken 10 minutes to do 3 photos of 18
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Classic Mini, Land Rover Defender 90, Kawasaki GPZ550 Custom (Bought from Fladdem), Honda VFR400 NC24, Suzuki GSXR400 gk73a

[MiniMan96]

Finally been able to download a couple of photos off my phone. I completely forgot that I had chopped the rear of the frame for a smaller seat unit.

Ill have to take a photo of the fibreglass seat unit I bought for £20 which fits my frame perfectly now.

Unfortunately it won't let me upload most of them due to them being tom large Anyways, here are some photo's of the bike (not my naked body)
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Classic Mini, Land Rover Defender 90, Kawasaki GPZ550 Custom (Bought from Fladdem), Honda VFR400 NC24, Suzuki GSXR400 gk73a

[stinkwheel]

Point of order.

That's a GPz550.

The lower case z indicates air-cooled.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[.Chris.]

[hellkat]

I've got a dead one parked up outside my place if you want to trailer it away for parts.
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Not nearly as interesting in real life.

[.Chris.]

[hellkat]

Yeah okay it might be a 500 actually, sorry ... :sheepish:
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Not nearly as interesting in real life.

[.Chris.]

I remembered correctly
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Chris
1985 Kawasaki Z550F

[hellkat]

In fact its an EX500
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Not nearly as interesting in real life.

[MiniMan96]

[Vracktal]

[Robby]

[talkToTheHat]

The optimist in me wants to see this happen. The enginineer in me thinks this is doomed unless you have access to some serious machine tools. Lathe and a milling machine, preferably cnc. Access to someone who can operate them also. Unless work is a machine shop? Surprise me, i want to see this.
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Bandit. does. everything.

[Robby]

It isn't so much the tools as the ability to design something that will work. Bear in mind the OP is trying to fit a single sided swingarm without the original frame of the bike is came off, which is somewhat useful to measure the width and diameter of the spindle holes and the location of the upper shock mount. Once that bit is worked out, you need to know the offset and the range of motion so the frame and wheel won't try to touch each other. Just getting the torque arm right for the rear brake is a bit of work.

Then at the front end, changing yokes can be as simple as pressing out the GPz pin and pressing it into the new yokes - if the pin diameter is the same. It may just be case of finding the right size bearings to use the new yokes complete. Then the next bit of fun is getting the forks the right length - they're probably too short, given the rake of a GPz compared to anything modern with decent forks. Then there's the fun of getting springs and damping right so that the suspension works.

Cutting out bits of metal is the easiest and cheapest part of the whole project.

It's a shame, because the GPz looked like a proper 80s naked bike, and isn't far off being old enough to start getting desirable and expensive. I suppose projects like this are good news to anyone with an original example they want to sell. One less to compete with.

[Rogerborg]

[MiniMan96]

[Rogerborg]

[talkToTheHat]

[Rogerborg]

[Moxey]

That's a little too good condition I think for chopping to bits but what's yours is yours.

I've stated before in this thread that its usually those who crack on and do the job that end up with something at least somewhat roadworthy, with few exceptions most turn into a fantasists bodged project left to rot or beg ridiculous money on ebay as 'almost 100% finished'.
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Current: 02 FZS 1000 & 91 Royal Enfield Bullet 350 Some Bike Pics...
'I was too busy paying attention to pay attention'