Zephyr 550 Bosozoku Style 2022
I could write at great length about the motivations for this project and my fascination with certain subsets of Japanese culture. But let's stick with the facts and the timeline.
I will do my best to explain things as you read on.
Summer 2021:
My friend Chris F and I joked about building a wacky Japanese style Bosozoku bike. Mostly joking, but he earnestly agreed to offer substantial help if I wanted to really do it.
These are what we talked about. We pored over 1000s of photos of contemporary custom bikes from Japan.
A subculture that was originally spun off in the 60s, 70s and 80s as extreme Japanese counter culture, is still alive and well cultivated in the land of the rising sun.
Bosozoku! (Or maybe Kyushakai)?
For historical and contemporary context:
Vice Documentary on the subject
Super good interview/documentary
**Admission of Ignorance**
I am not an expert on this history or culture, I have just read articles and follow the current culture on social media using internet translation tools.
December 2021:
I found the perfect US domestic bike. A 1991 Kawasaki Zephyr 550. The bored out clone of a very common Bosozuku style bike in Japan, the Zephyr 400.
Rescue and Mechanical Restoration:
First steps were to make the bike an operable cycle before I threw volumes of time and money into the wacky aesthetics of the Japanese Bosozuku style.
February 2022:
After about a month's worth of work, it was roadworthy again.
Onto cleaning and polishing
March 2022:
Design and International Orders:
Walking from Back to Front, let's get into the the features of the special Bosozuku style:
- Smoked brake light with strobe in light and under body.
-"Shrimp Tail" addition to rear cowl. Some of these are quite large on the extreme bikes.
-Aftermarket exhaust: Got a really good deal on a "Mad Max" branded bolt on 4-1 great sounding exhaust from Webike Japan. It was a bolt on part for the Zephyr 400m, so it fit the 550 perfect. No fabrication needed.
-"Three Tiered Seat" or "Sandan Seat"
-Upturned turn indicators (both front and rear)
-Horn: May be PA style or multiple air horn style.
-Rotating flashing emergency light.
-Cup holder/baseball bat holder. The baseball bat harks back to the old days when Bosozuku style wasn't just an aesthetic, but a way of life as an outlaw in an organized motorcycle gang. A way of life that included gang violence. Opting for cup holder.
-More BEET style, customization of side covers and stator cover to mimic BEET branded products from Japan. The best way to describe BEET, is with an analogy to Nike or Gucci. It is a high end racing brand in Japan. The more high end aftermarket pieces of BEET accessories you have on the bike, the greater your reputation for flashy expenditure into the machine.
-Handlebars akin to "Rabbit ear" chopper bars. Many Japanese custom bikes use nearly unusable bar arrangements, just to be as extreme as possible.
-I wanted a full fairing, of the "Rocket" style in Japan. A universal fit part that is made in abundant quantities in the domestic aftermarket marketplace of Japan.
-After several months of trying, the costs of shipping an entire fairing just became unrealistic for the overall project (greater than 1000). The size put it in the same category as shipping a whole car bumper.
-In the end we cut up a Dunstall fairing from Airtech-Streamlining. With much effort, I turned the three piece kit into a single piece.
-A Sev Marchal branded headlight. The black cat logo is another staple of Japanese bike builds.
See link for the France/Japan connection.
https://www.hagerty.com/media/motorsports/the-legend-of-marchal-motor-racings-lucky-black-cat/
Mock up of a used Dunstall fairing scored from Ebay out of California.
I purchased a used "Three Tier Seat" off of Japanese used auto parts website, Croooober.com. Really the moment the build crossed from fantasy to reality in my brain.
Onto disassembly and painting of wheels and brakes.
April 2022:
I made some custom hoodies.
The back logo is pulled directly off the Kawasaki OEM Owners manual for the Zephyr. "Story of the Wind" is just too good.
Next were flashing strobe lights and a noisy horn. Horn makes horn noises and siren tones.
Then focused on work for paint detail.
Sketches.
I accidentally ordered a minibike Rocket style fairing from Japan, it was an expensive mistake.
I was able to order a genuine rocket windscreen from Japan, we hoped and prayed it would fit our fairing.
Next was the base red paint for Fairing and body. (note trimmed up Dunstall)
I commission my friend Keith for custom graphics.
May 2022:
On to graphics application and fairing stripes. So, so, difficult. Chris really wanted to murder me after this part of the project I think.
We spent a few months looking for a good gold for the wheels. (turns out its impossible to get a gold chrome without full anodization or powder coat).
REASSEMBLY
(Note, most work was done after work on weeknights, especially in the colder months and during hangouts on Tuesday nights.)
June 2022:
Final Reassembly and small touch up detail work.
Cherry on top was a proper 7-11 JDM photo shoot!
(A staple motif for Western JDM culture)
I was so super excited to make this photoshoot happen. Ive seen so many cool JDM builds over the years in the classic 711 shot.
Luckily my friend Ed, who is talented amateur photographer, shared my enthusiasm and got the shots.
I am over the moon to have this project wrapped up, and am currently enjoying ripping the bike all over Philadelphia.
While properly silly, it is an absolute hoot to ride.
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