Hi everyone, howdy from the scenic ocean roads of aussie! Thought I would sign up and share my long time project with a long time love, my old XZ550. Very uncommon bikes here, so im glad theres so many entheusiasts around the globe. This is my baby, owned her 3 years ago then sold her due to lack of space and a breakup, however 3 years later I tracked her down again to be restored as she deserves!
bit of a muddle bike I think, 82 with some 83 parts, though the most important thing is that the engine and frame numbers match, 0000629! nice staintune pipes, everything in need of a GOOD freshen up. 42 000km on the clock, ran strong when I had her a while ago.
ideas are to strip the bike, freshen the engine up a little bit, lots of polished metal, painted everywhere and in great condition hopefully, still unsure on the paint scheme but im thinking retro with a metallic white with red accents.
The only major issue I need to sort out, is there is a wiring issue, it keeps blowing the fuse to the indicators.
(http://img200.imageshack.us/img200/4764/dscf2804medium.jpg)(http://img148.imageshack.us/img148/5783/dscf2806medium.jpg)
(http://img188.imageshack.us/img188/5167/dscf2807medium.jpg)(http://img194.imageshack.us/img194/9807/dscf2805medium.jpg)
and my daily rider!
(http://img194.imageshack.us/img194/9118/dscf2808medium.jpg)
just a heads up on the paintscheme:
frame - fresh gloss black
ancillary parts like the shaft, forks, etc - highly metallic gunmetal
engine, forks etc - sent away for cleaning and chroming or polishing :D
wheels: gunmetal with a polished lip
engine: to be stripped and inspected, new gaskets seals and any repairs needed (more than likely just get a new primary chain and timing kit for safety)
if need be, ill rebuild it with 20 thou pistons at most
carbies: rebuilt and jetted (by a shop!) to try to get it running smooth)
exhaust: need a shop to replace the headers that were damaged when someone decided to remove the exhaust collet with force
also in the mix:
- new headstem bearing and wheel bearings
- new screen
- rebuild the forks
- rebuild the brakes and replace the discs / pads / lines
- clutch!
- rebuild the starter since im pulling the motor
- recover the seat
- enjoy riding it!
nice Chris!!! Lots o pics!!
Hi Chris & welcome
Just so you know, the XZs that were sold in NZ and Australia were the same spec as those sold in europe, so what the yanks call 82 & 83 versions doesn't apply. The gearing is different, and all had the short handlebar risers and progressive fork springs. but no air caps. They have the same carb as the US 82, but with the vacuum flapper installed, no fuel gauge. Check out the different model streams on Wikipedia which I think is fairly accurate.
I know of at least 10 550s and a bunch of 400s in New Zealand, so you are not entirely on your own in Oceania, looks like you are in need of some side covers. Let me know what you need.
White will look great. Mine is a Spies-Hecker Xirallic White Pearl with House of Kolor Brandy Wine Kandy for the stripes in the XZ550S style (slightly modified). It loooks FAB. There's a really good gallery on xz550.de that may give you some painting ideas. My current favourite is the black one with a red tank top
Bearings are easily obtained, make sure you get the taper steering bearings though
Screens are available from godiva.co.nz
Brakes are ideally done with braided stainless
Thanks alot :) yeah ive got some taper head stem bearings being watched on ebay at the moment as well as some other nice little bits. and thats good to hear about the year models here. those screens on godiva are a great price, so i will definately be ordering in from there (was quoted 260 for one locally).
Cant wait to start rebuilding it, just gotta get my car project out of the way first (at least mostly done for rego) Ill check out that site as well for paint ideas, id love a white pearl but ive never sprayed it before, i tend to stick with basic acrylics since thats the only experience ive had.
Nice looking bike. I'll bet there are quite a few who will be interested in those staintune pipes. Any chance they are still in production?
:) Hi Chris, welcome to the ROV mate...its always good to see and hear from new blood.
Any help, advice, part(s), etc, etc that you need don't be afraid to ask. We are ALL in the same boat here ;)
8).......TIGER....... 8)
I'm not sure if they are still in production, but they are going to look absolutely schmick after I give them a polish up with Autosol.
Just bought some supplies :angel:
All duplicolor because I love how their paint applies and have used it on many race bikes and all my previous bikes with amazing results for being rattle can paint.
1 x Paint stripper (K+H)
1 x Rust converter (K+H)
2 x Primer
2 x "Wild Violet" dark metallic purple
2 x Gunmetal metallic
4 x Clear
2 x Gloss Black
HUUGE amount of sandpaper, tack cloth, cleaners etc
plenty of autosol and autosol for plastic (owned about 10 tubes all up already)
3 x wirebrushes
RAGS RAGS RAGS
So far, looking at the bike being dark metallic purple with gunmetal or black frame, and gunmetal or black ancillary parts. Tinted screen, and attempting to strip back as much off the engine as possible so it can be polished up along with the shaft drive possibly (otherwise that will be gunmetal too)
Stay tuned! I've finally got some days off soon so I'm planning on having the bike stripped in 1 day. prepped in the other and work to commence on the third, weather permitting.
Nice one Chris. I'm across the ditch in Auckland with an 82 550. Done a few mods to mine, great handling bikes for their age. I'm at pickteam@xnet.co.nz if you ever want a natter.
Chris , I can't speak on Duplicolor paint , down under, but here in AZ. it is not the least gas resistant, as it used to be! A spill while fueling will pucker and bubble the paint and pretty much destroy the paint job. if this is a concern to you , you might paint a tin can and after a few days sprinkle a bit of gas on it and see what you have.
hey Glyn! cheers, nice to see some guys around this region :)
and RickG, I'll keep that in mind, however most of mine have faired fairly well with fuel spills, the two road going bikes I resprayed with duplicolor lasted a fair few months of commuting with no signs of damage, im fairly careful when I fuel however so it may have been the reason.
Progress started here, cleaned up the plastics so I could inspect them, disassembled the front fairing, however I need to remove rivets to get the "air conditioning" flaps out of the lower pieces, and started sanding up the front fairing.
LOTS of more body work to go on this beast, will require a fair amount of fill primer too.
(http://img40.imageshack.us/img40/1849/dscf2698medium.jpg)
(http://img40.imageshack.us/img40/3234/dscf2690medium.jpg)
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looking good...keep the photo blog going.
Yes!!! Im gonna have to be doing this too,,, I dont have the pieces in hand yet.. Thank you for the preview!!
Quote from: funkamongus on August 15, 2009, 11:13:19 AM
Yes!!! Im gonna have to be doing this too,,, I dont have the pieces in hand yet.. Thank you for the preview!!
Can't wait to see your project! what are you thinking of doing?
Just a quick update, I finish my work block this nightshift, so I now have 6 days off as of tomorrow, so work will go full swing into the XZ550, expect to see some paintwork being completed :)
Also I got a new purchase. XZ550 wiring harness/loom in "ok/decent" condition for $19, so i might keep that one handy, and strip my old one and rewire it. have it as a backup. This might be the quickest way for me to hunt down these wiring gremlins.
12:14pm Progress report:
Tank has been removed and drained, for 3 years sitting outside it isnt as bad as I thought, the fuel tap is perfectly operational, there was no grit at all on the petcock or filter. The fuel is a dark dark colour but still smells like petrol and isnt a different viscosity or full of chunks. I processed about half a gallon through the petcock filter before removing it and inspecting it. the tank has been flushed since, no real signs of rust within the tank.
I'm preparing to strip all the paint off the tank to inspect for any rust spots but its looking promising at the moment. Thankfully before I sold the bike the tank was completely flushed with new fuel put in.
EDIT: oh and my second hand wiring harness came via express post just then too!
Todays progress is finished. The tank took 2 hours to strip as much as I did, plus some sanding and bogging. alot of other bits of paint that I could remove but I havent.
The underside of the tank was roughed up and coated with some rust converter and will be sprayed with some of the gunmetal paint just to coat it.
the fairings were all sanded and washed ready for paint.
I flushed out the tank a bit more. I will be giving it a rust treatment for safety and a POR15 coating. ALOT more preparation on these panels especially the tank to go before I lay some primer. I want it to be as perfect as possible.
Purchased: some more etch primer and fill primer.
Pictures:
(http://img15.imageshack.us/img15/1048/dscf2835medium.jpg)
(http://img15.imageshack.us/img15/6046/dscf2837medium.jpg)
(http://img502.imageshack.us/img502/8426/dscf2838medium.jpg)
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(http://img190.imageshack.us/img190/8948/dscf2849medium.jpg)
That is some fine looking apple juice you have there. Looks as potent as CIDER!.....LOL
Progress report 22nd August.
Layed a coat of etch primer on most parts, needs resanding and recoating on most of the fairings tomorrow though. Layed a very thick coat of spray putty on the tank and a light coat on the top fairing. the tank is coming up schmick! however the top fairing will need a few touches here and there. the spray putty is a wonder, though the spray pattern is horrible.
(http://img200.imageshack.us/img200/1294/dscf2851medium.jpg)
(http://img35.imageshack.us/img35/6586/dscf2852medium.jpg)
(http://img195.imageshack.us/img195/1753/dscf2854medium.jpg)
(http://img223.imageshack.us/img223/7159/dscf2855medium.jpg)
pretty good job. Have you thought about filling in the bottom of the tank, where the seam area is, with body filler? It will smooth out the tank very nicely.
how do you mean? as in filling over where the little strip of metal joins at the base? kinda like someone crimped it?
EXACTLY. Take body filler and make a few coats until it's flush. Then it will look REAL SMOOTH.
Progress, completed a full engine removal and semi-strip in a total of 1 hour. All in all it was a simple procedure that cleared up alot of doubts I had previously. And dont worry!!! I am labelling and organising my parts as you read this. And yes... I am cleaning up my garage and front yard.
lovely and very ill-thought out engine stand, i need to redo-it to allow access tothe lower parts of the motor.
(http://img210.imageshack.us/img210/8033/dscf2856medium.jpg)
(http://img268.imageshack.us/img268/2726/dscf2876medium.jpg)
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You might want to consider stuffing some rags down your carb throats. Stuff happens.
i tend to go overboard and stuff oil soaked rags in the exhaust ports and intakes of my engines when I pull em. but at the moment, its just wrapped in plastic.
noticed you cut a coolant tube... don't cut those upper ones because they are NLA
Quote from: Night Vision on August 23, 2009, 09:35:59 PM
noticed you cut a coolant tube... don't cut those upper ones because they are NLA
uppers are semi corroded too... doesn't matter, same as when I did my 1981 Toyota Corona, it will be custom coolant piping, sucks ass to do, but its the only option.
Quote from: Night Vision on August 23, 2009, 09:35:59 PM
noticed you cut a coolant tube... don't cut those upper ones because they are NLA
You can replace them with a couple of odds and ends.
part number GoodYear 63244.
a 3/4 to 3/4 coupler
3/4 heater hose about 16 inches (it will be cut down)
is what I used to replace my hose that ran along the right side. It now looks like this:
(http://www.pbase.com/moffetb/image/80754141/original.jpg)
thanks brian! thats a good help for when I get to that stage. got ALOT more to go before I reach that time yet though.
Update from today, got busy with some chemical stripper to remove the 30 odd years of paint and grime. As expected the frame is covered in a decent amount of surface rust and horrid stuff.
I removed the brakes and attempted dismembering them, however they are seized shut, so Ive soaked them in some WD40 overnight, will get the compressor running tomorrow for that.
I'm very anal, and this bike is going to be a LARGE labor of love by the looks of it. I'm going to have to strip the frame to its component pieces and get it blasted or manually remove all the surface rust and fix it all up. Day by day this is becoming close to a total rebuild.
just for inquiry, I know someone mentioned different parts for brake pistons and seals, does anyone have them on quick reference?
I recall that the kits from an RD350 or RZ350 can be used for the calipers.
RZ350
http://www.hvccycle.com/hvcpartscatalog_files/yamahabrakes.htm (http://www.hvccycle.com/hvcpartscatalog_files/yamahabrakes.htm)
more of the frame stripped. Went to test some rust stripper. worked decently, lots of elbow grease to do here unless I get it blasted.
(http://img526.imageshack.us/img526/6640/dscf2883medium.jpg)
(http://img523.imageshack.us/img523/1255/dscf2884medium.jpg)
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Hey, what ya know. The Vision stripped down bare naked kinda resembles a Shwinn chopper pedal bike.
Bet goes on center stand real easy.
Quote from: QBS on August 25, 2009, 09:56:08 AM
Bet goes on center stand real easy.
daaaamn easy :P I was even able to flip it upside down with my bare hands.
yeah, I had white walls on my Schwinn Corvette! It was cool in 1956.
Progress, I decided to go with the chemical route over sandblasting for the frame. Lots of paint stripper, wire brushes and rags. Its proceeding quite well, frame is coming up as a nice shiny brushed metal look. after the rust is dealt with and the rest of the paint stripped I'm not quite sure what I will do! the frame looks quite good as a shiny brushed, possibly polished metal look.
Well, my 100 dollar venture with paint stripper, rust removers and all myriad of chemical "SURE FIXs" was a waste, my brain snapped and I realised... wait.. why didn't I use a wirebrush and a drill before.
EDIT: thread name amended
The finished product at the moment is not finished, theres still more work to be completed on that swingarm, and I will probably finish off with some 1200 grit hand sanding and Autosol. mmmm polished.
So I did.. and wow... this is 1.5 hours work.
more stripping.
(http://img168.imageshack.us/img168/3962/dscf2910medium.jpg)
(http://img35.imageshack.us/img35/8761/dscf2911medium.jpg)
before
(http://img186.imageshack.us/img186/9281/dscf2914medium.jpg)
after
(http://img406.imageshack.us/img406/5413/dscf2912medium.jpg)
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looks good to me... the undercoat is as important as the top coat.
use a good primer and make sure it drys and do several coats.
This all looks soooo familiar to me, I went with the "send it to someone else for gritblasting and priming".
true, that is the smart thing to do... but what is a labor of love without some hard labor (besides, its an excuse to drink beer at 10am)
Looking good. How hard was it to get the engine out and onto the stand? Did you need any help to do that or could you man handle it.
LOL... those pictures all look very familiar and bring back memories. Some scary, some good.
David
I've been suffering a bit of fatigue for a month and a half... so I'm hoping its not in a bad way, bloodtest results and my next followup with the GP should hopefully sort it out, so I haven't managed to work on the bike for more than an hour without having to give up and just relax.
The engine itself wasn't too bad, still need a trolley jack, a plank of wood and at least 2 people though.
and I know the feeling of horror when I see random parts on the bike, so close, yet so so so very far. I had a chat with my local yammy dealer (since they are the ones that I bought the Hyosung off... and its being repaired again). there is ONE set of piston rings available on the other side of Australia... there is also a set of exhaust headers. they also said "I'm truly shocked... I thought I have seen every Yamaha before"
What is your opinion of the Hyosung? How long have you had it? How many miles on it ?
My hyosung was bought new (2009 mod) and its fantastic for the price AS LONG as you stay ontop of your maintainance, and ensure that all bolts are tight. also a 100 dollar racestand is handy to have to make sure that you can do work at home on it. I have the carbie model and it is fine, however I've test ridden the new fuel injected version and its 1000000x better!
I've owned it for 2000 miles with 2 breakdowns covered under warranty, the fuel tap was dodgy, and a 50c oil seal on the sidecover of the engine displaced itself and the bike dropped oil a bit. at least the 2 year unlimited km warranty is good. Yoshi pipe sounds very nice :)
Thanks for the reply. You're the first Hyosung owner I've had an opportunity to get real world feedback from.
Im a realist though, I didn't but the hyosung to learn on or for any other reason except as a budget commuter bike that I can thrash a bit on the weekend. For the price it serves my purposes fantastically. Its not a bike that is used to get you 'street rep' however, anyone that doesnt know much about bikes for some reason absolutely loves it to pieces. more than likely because its loud, gruff sounding. and its all black.
more pics for the xz550!
check out my bikepics site for any other projects running at the moment. My small business is up and running. 2 cafe racers sold within 4 months at 3100 each! for a 1980's 250cc bike! nice 1500 profit on each. got the latest cafe ready to go too. unfortunately no pics on the previous cafe. but the current one is being documented.
http://www.bikepics.com/members/wrtcustom/
and to steal someone elses completed cafe of the same model, this is basically what my cafe's end up like. however I fancy a more gloss acrylic paintjob, and also my polished aluminium ram-intake setup :D does nothing on a 250 but it looks very keen. sounds great too.
(http://p1.bikepics.com/pics/2007/08/04/bikepics-983796-800.jpg)
(http://img12.imageshack.us/img12/5149/dscf2928medium.jpg)
(http://img196.imageshack.us/img196/7069/dscf2933medium.jpg)
(http://p1.bikepics.com/pics/2009/09/11/bikepics-1778161-full.jpg)
Work began again on the bike, since the car took up all of yesterday.
Got the filler sanded down on the tank, and a fresh coat of primer grey.
Ditto for the front guard and front fairing.
I tested out the "Wild violet metallic" paint, and gee, its actually quite amazing. Dark dark purple metallic. very nice.
I will finish up the front wheel and swingarm today so the bike is ready to reassemble to a rolling frame tomorrow.
pics to come.
FINALLY I got into gear and laid some paint down. all of the parts have now been filled. I decided to work on the gas tank today and keep each paint job separate so I'm not rushed (a common mistake I make).
-Sanded the primer filler down to 600 grit, clean, dry, and white spirit.
-Sprayed 2 coats of grey primer. dry, sand, clean, dry, spirit.
-Sprayed 3 coats of the base colour, Gunmetal metallic.
-Sprayed 3 coats of top colour, Wild Violet metallic (not as metallic as the gunmetal)
result? I love it. its not as bright as the plain wild violet was when I test sprayed on white paper. its quite metallic, but very fine particles. really pops in the sun, but doesnt show in the shade.
The next step? its acrylic and metallic, so it needs to cure for a few days then a MINOR sand to remove imperfections, and then to be cleared. once its cleared x 2 or 3, ill let it cure again and then buff it to hell.
images you say? here they are. halfway through the drying process, so it should become nice and satin once dried (and it did) I also apoligise for the quality of the pictures. I haven't had any batteries for my good camera for a few months, so ive been using a crappy little one.
(http://img23.imageshack.us/img23/9224/dscf2947medium.jpg)
(http://img42.imageshack.us/img42/4458/dscf2954medium.jpg)
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Nice job. I bet it really does POP in the sun. Did you use a rattle can or a real spray gun?
As you can probably notice with my state of the art gas tank holder, I'm obviously a professional :P
*cough*
... ok its a rattle can job. but to be honest, I've been spraying this way for 8 years and its never let me down. i really should learn how to spray with a gun, but yeah... never had the space.
Finally its starting to take place. Its now a rolling frame for easy of movement purposes, and so I can clean up the porch.
Still have to polish the forks and the wheel hubs more. oh and finish the paint on the tank.
The paint is SOOO much darker in real life. I think i need to get my other camera working. :( it looks so lavender in the pictures.
(http://p1.bikepics.com/pics/2009/09/22/bikepics-1786406-full.jpg)
(http://p1.bikepics.com/pics/2009/09/22/bikepics-1786410-full.jpg)
(http://p1.bikepics.com/pics/2009/09/22/bikepics-1786412-full.jpg)
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(http://p1.bikepics.com/pics/2009/09/22/bikepics-1786416-full.jpg)
WOW shes really coming along!!!!
that drive shaft/swing arm looks ALOT smaller in black...
ummm... did you know your fork lowers are pointed backwards? twist them 180 deg.
(http://p1.bikepics.com/pics/2009/09/22/bikepics-1786416-full.jpg)
Quote from: Kid Jedi on September 22, 2009, 11:36:33 AM
that drive shaft/swing arm looks ALOT smaller in black...
I think that's because the rear tire is oversized.... sorry Chris, not trying to be picky
Yes, i noticed that yesterday :'( I was hoping nobody would notice until I changed them round today.
and the tyre sizes are 120/90 and 100/90 for reference :P
I'm also appauled to know it took me 30 minutes to work out why the bike looked like a cruiser / chopper.
rake yo?
huh.. run em backwards to make a sweet chopper...
NO BAD KID JEDI! >:( BAD! >:( you have enough projects already! There is a shark fairing IN YOUR BED and a Cylinder head, pistion, Jug thermostat housing and crankshaft on your Coffee table!
Fine.... :(
Quote from: chrisw on September 22, 2009, 08:01:02 PM
and the tyre sizes are 120/90 and 100/90 for reference :P
That's what I run on my 1983 Vision. Metzlers to be exact.
Brian
I tried those on my 82 and she felt really sluggish. going to run 90/90 on the front and 100/90 on the rear, but might be stick with 4.0
Mine will have new tyres. Most likely a set of medium compound Shinko's (I love em, except for the wet performance)
either that or scrounge around the shops here for a set of pirelli's
At the moment its running a metzeler front and a brigestone rear. rear is great, but 4 years old. I'd rather not tempt fate.
I had one of those Bridgestone Spitfire 120/90's... that's a big tire regardless of the numbers
yep ;) thats what this one is too.
Actually, you have the right fork leg assembly on the left side and visa versa.
Through the fantastic power of an Olympus borescope I have had a good long inspection of the combustion chambers of the XZ550 engine while its out of the bike. Saving a full strip down this is a great method of inspecting the guts of the beast and it only takes a few minutes.
my conclusions of the 42 000km old engine;
1. Its VERY clean, slight oil discoloration as expected but NO coking, NO buildup soot or carbon, its amazingly clean and smooth.
2. NO scoring or damage to the bores / pistons / heads / valves.
3. Everything just looks well.... amazing. the piston design suprised me, a very odd looking domed piston.
The engine basically looks just run in, not 42 000km old! im very impressed.
did you plastigauge anything? did you check the actual bore diameter?
well, im sure its well worn, but im talking about the visual inspection :) as per the previous reply I haven't actually stripped it down (and been able to measure). but from the funky borescope with awesome levels of macro viewing power, it looks ALOT better than expected. I was expecting a coked up worn out engine with rust and crud everywhere.
So I've been busy with work lately, that might change soon as im REALLY after a career change with less stress and more family/friends time, the money isn't great with the current job anyways.
so I had 2 hours spare as I was doing some housework today (removing garbage to the tip to be precise, after 6 bike projects, there was over 90KG of rubbish parts!
just some paint and assembly, not put back together properly, just placed on softly. Still needs to be clearcoated and buffed all over, and no, I haven't fixed those forks yet :P
How it started...
(http://p1.bikepics.com/pics/2009/09/09/bikepics-1776656-full.jpg)
Current State
(http://p1.bikepics.com/pics/2009/10/24/bikepics-1812678-full.jpg)
(http://p1.bikepics.com/pics/2009/10/24/bikepics-1812679-full.jpg)
(http://p1.bikepics.com/pics/2009/10/24/bikepics-1812680-full.jpg)
(http://img148.imageshack.us/img148/8471/dscf3079medium.jpg)
Next bit to tackle!
(http://img39.imageshack.us/img39/5425/dscf3090medium.jpg)
the PURPLE REIGN ... i mean XZ550 is getting there *cough prince cough*
(http://p1.bikepics.com/pics/2009/10/29/bikepics-1816726-full.jpg)
hey if prince doesn't have to figure out his gender than neither does your bike!
:D
I think the purple looks really nice with the black swing arm, and the silver motor be a great accent. I think it will come together great
I do too.. You should polish those rims too!!! and the fork lowers!!!