KAWASAKI Z550F
John Vassallo gets down to it…
Back to my latest purchase then, my 1987 Z550F! I bought it because it was cheap, and will hopefully give me enjoyment cleaning up, repairing and riding it.
Since the last issue I’ve had a good tidy up of my garden, the reason being a man in my local pub (The Windmill) rebuilt my patio, hence he needed plenty of work space. This now tidy area will surely benefit me too, and the Zed! Wheeling the bike about on the patio reminded me that flat front tyre needs changing pretty soon. I was also careful not to touch that rear brake, through fear of jamming it on.
After this little workout, the first thing off was that torn seat. Then I tried unlocking the fuel cap. After several days of spraying penetrating oil into the key hole, it still failed to open. The lock wouldn’t even turn! By this time I was angry at getting nowhere! Taking a large screwdriver to prize it open did the trick. Damaging the fuel cap wasn’t a problem, but I’d put a small dent in the tank. Maybe I should have been more careful? I didn’t want to ask for help for what seemed a simple task, but you live and learn.
The first thing I noticed was the horrible smell of the old fuel, then the corrosion inside. I mustn’t be surprised though, the last tax disc expired in 2004. The fuel hoses were removed, then the connector for the fuel gauge and the tank was free. At least the underside looked okay. The side-panels came off easily and are in good condition, lugs intact and the badges present on both. With this removed, I could see the electrics looked good. It even had a Kawasaki tool kit!
Now was a good time to look at that seized rear brake pedal. With pressure it would travel downwards and stay there, not to return. The securing bolt came undone without drama, releasing the pedal. Now for some PMA Multi Lube. I applied this spray to the spline and surrounding area every day for a few weeks. The result was worth the wait as it had freed up the mechanism. This stuff works!
Next was to look at that corroded front mudguard: only four 13mm bolts held it on, two of which came undone without any struggle, the others ended up with rounded heads. So, I had to remove the front wheel – which needed a new tyre anyways!
The spindle had no split-pin on the nut, but a pinch bolt instead. Again, the nut was reluctant to turn and more Multi Lube spray was needed. After a few days of spraying it decided to move, with help from my pipe grips. Wonderful tools these things! A new nut replaced the one I’d rounded off.
With the wheel now off and forks resting on a bike stand, I could now access those remaining two mudguard bolts. Pipe grips needed again, but job done and replacements were sourced. The replacements I had in my stash were too long. After cutting them down the ends were jagged, not allowing a nut to bind. A friend’s dad (Fred) gave me a thread file a couple of years ago. I’d never heard of these until then, as I’m no mechanic, but these things are handy. I wire brush cleaned the first two bolts, a dab of copper slip on all four, then screwed them back in the fork legs for safe keeping.
That front tyre wouldn’t take any air, which was a shame as the tread seemed good, but best not to skimp. The years of grime came off the wheels, thanks to WD-40 and a few hours work and (after marking L and R on tape on the wheel) I took it to my local Watling Tyres, who fitted a new Avon Roadrunner.
Next thing to think about is how far to take this project. Knowing the engine runs means it’s not a total restoration. A friend suggested looking for a GPZ tank and panels. This would eliminate the need to tackle the corroded tank, I guess. Then there’s the torn seat to replace or recover (easy), the front mudguard to repair, and the front brakes need a complete overhaul. The engine needs a good service, and the chrome headlight trim will need replacing. You can see it’s suffered from being outside. The carbs, of course, will need removing and cleaning, which I will need help with.
Thinking ahead, I’ll need a good tidy up of the shed again, before anything else happens in there. One thing I learned when doing my LC was you can’t work in an untidy s-hole! Whenever I look through bike mags, other people always have tidier sheds/ garages than me. Surely they tidy up for the photo shoot? I did the LC with a leaking roof and a damp floor. I’ve since seen to this. I’ve also changed the flickering strip light to LED spots. More shelving also keeps stuff off the ground and working areas clear.
Lastly, I’ve attempted loosening the screws on the master cylinder cap. They (of course) chewed up so it had to come off. Luckily, the hose and securing clamp easily came off. The cylinder is now sitting level on the workbench. Hopefully the penetration spray will help the screws out. As I said previously, the bike came with original mirrors and they came off easily, so that’s something! cmm