1982 KZ550 proposed KZ1000 engine swap

[dxiw]

I have a kz550 that runs well that I used to learn to ride on. I've put about 1000 miles on it with no problems (its now at 12k total) and I love it to death. This morning I came across a KZ1000 from 83 that somebody was selling for parts. He said the engine runs well and has low mileage. I was thinking about doing a winter project where I drop the 1000 engine into my 550 bike. I was just wondering if anyone has any experience with engine swaps and how difficult this would be. I have a decent amount of experience working with mechanical things and engines so I am comfortable doing the work. I am just curious if anyone knows if the 1000 engine will bolt up or if I will need to machine some custom mounts. Also, I'd like to know if anyone has tried anything like this and what problems they have run into.

My second question is, assuming this is not possible (say it doesn't fit or something), does anyone know any good ways to squeeze some more power out of the good ol 550 (barring NOS or anything silly)? I am going to rebuild and clean the carbs this weekend which I'm hoping will help things a little.

[elr658]

Post your location.

Won't fit. You will only succeed in making scrap.

[Bilby]

I've got to agree with ELR- all that's going to happen is that you will ruin a good working motorcycle, I'm sorry to say. The frame and suspension on the 550 is not nearly strong enough or designed properly for an engine as powerful and large as the 1000's is.

In terms of squeezing more power from the 550, I would suggest doing all of your maintenance first to make sure it's providing the power it should in the first place. A full round of fluid swaps, plus air and oil filters, adjust the valves and adjust / lube or replace the chain. Fresh tires and proper balance and inflation also help a lot.

After that, other types of repair / maintenance often help. Wheel bearings, steering stem bearings, worn sprockets, timing chain tensioner; all of these things can sap power from your bike. Suspension issues can also make the bike feel slower- rebuild the front forks with good seals and fluid, and replace the rear shocks if they are worn out ( if they're original, they're worn out ). You may be able to get properly-tensioned fork springs for your weight and riding style, if you can, do it. A cartridge emulator like race-tech sells can also help the front end work better.

After that, you can do the full roll out to beef power:
-aftermarket exhaust
-K&N pod filters
-smoothbore carbs
-bore out cylinders
-high compression pistons
-more aggressive cams
-back cut the transmission
-TURRRBOOOOOOO

and many other things that cost lots of money

Cheers!
Bilby

[dropdfocus]

Let me save you the time, money & hassle... Adding the mods will gain you some extra power, but not enough to really justify the money spent. Been there done that on an '81 550. Save your money for a larger cc bike.