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1981 GSX1100 Katana Based Project

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    Originally posted by Rob S. View Post
    You'll have to chain this bike down at night. Else it'll just float away.

    Would have to use an aluminium chain to keep in step with the build.
    Badgezz, we don need noh stinkin' badgezz!
    Shin-Ken 1074
    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

    Comment


      Starter motor is now in place, starter and bolts = 1,522 grams.

      Running tally = 150,592 grams.
      Badgezz, we don need noh stinkin' badgezz!
      Shin-Ken 1074
      1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
      1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

      Comment


        The starter motor cover is one of the parts I made in carbon, the first two were total fails as you can see with this sad example.

        Starter cover 1 by Max Mutarn, on Flickr


        Got it on the third try.
        Carbon cover by Max Mutarn, on Flickr
        Badgezz, we don need noh stinkin' badgezz!
        Shin-Ken 1074
        1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
        1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

        Comment


          OEM steel starter cover.


          SZ OEM starter cover by Max Mutarn, on Flickr


          Carbon cover and bolts.

          Carbon cover and bolts by Max Mutarn, on Flickr


          DW Carbon Cover by Max Mutarn, on Flickr





          Running tally = 150,617 grams.
          Last edited by Shin-Ken 1074; 11-04-2023, 01:48 AM.
          Badgezz, we don need noh stinkin' badgezz!
          Shin-Ken 1074
          1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
          1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

          Comment


            Replacing steel parts with aluminium parts has helped to reduce weight for the DW 180 however, there are times when steel is lighter than aluminium. What form of skullduggery is this! The OEM clip-ons are solid aluminium and with the bar weights come in at 1,474 g. I found a used set of hollow steel clip-ons with aluminium bar weights that are 1,153 g. And the steel bars are also adjustable so the angle can go from a flat bar position down to the point where they will crush your fingers against the tank on full lock.

            OEM bars.

            OEM bars by Max Mutarn, on Flickr


            DW 180 bars

            DW bars by Max Mutarn, on Flickr



            Last edited by Shin-Ken 1074; 11-04-2023, 10:33 PM.
            Badgezz, we don need noh stinkin' badgezz!
            Shin-Ken 1074
            1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
            1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

            Comment


              I bought these bars because they are lighter than the stock bars however, I really like the additional feature of adjustment, from flat bars to full on drop bars.


              DW bars 2 by Max Mutarn, on Flickr


              Dw bars 1 by Max Mutarn, on Flickr


              Running tally = 151,770 grams.
              Last edited by Shin-Ken 1074; 11-04-2023, 10:33 PM.
              Badgezz, we don need noh stinkin' badgezz!
              Shin-Ken 1074
              1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
              1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

              Comment


                Carbon chain guard now installed.


                DW carbon guard by Max Mutarn, on Flickr


                DW carbon chain guard by Max Mutarn, on Flickr


                Running tally = 151,918 grams.
                Last edited by Shin-Ken 1074; 11-04-2023, 10:31 PM.
                Badgezz, we don need noh stinkin' badgezz!
                Shin-Ken 1074
                1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                Comment


                  Shaved oil filter cover, Ti nuts and washer and filter. No oil in engine at this stage as the DW will be going on the scales dry.



                  DW oil cover by Max Mutarn, on Flickr


                  Running tally = 152,193 grams.
                  Badgezz, we don need noh stinkin' badgezz!
                  Shin-Ken 1074
                  1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                  1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                  Comment


                    Cleaned up the clutch before fitting the newly painted cover.

                    DW clutch 1 by Max Mutarn, on Flickr


                    Clutch cover ready to go.


                    DW clutch cover and bolts by Max Mutarn, on Flickr

                    DW clutch cover installed by Max Mutarn, on Flickr



                    Running tally = 153,179 grams.
                    Badgezz, we don need noh stinkin' badgezz!
                    Shin-Ken 1074
                    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                    Comment


                      Saved a few grams swapping the OEM rubber grips for foam grips that are less than half the weight of the OEM grips.

                      OEM grips by Max Mutarn, on Flickr


                      Foam grips by Max Mutarn, on Flickr
                      Badgezz, we don need noh stinkin' badgezz!
                      Shin-Ken 1074
                      1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                      1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                      Comment


                        And they absorb some high pitched vibrations too
                        GS1000G '81

                        Comment


                          I always liked foam. Are they GrabOns?
                          1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

                          2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.

                          Comment


                            Originally posted by Shin-Ken 1074 View Post
                            Cleaned up the clutch before fitting the newly painted cover.

                            Clutch cover ready to go.

                            Running tally = 153,179 grams.
                            did you remove weight from the clutch cover ?

                            Seeing how far you go to save weight, did you consider a billet clutch cover, or one with a window ?
                            Expensive stuff.
                            Last edited by Rijko; 11-05-2023, 08:19 AM.
                            Rijk

                            Top 10 Newbie Mistakes thread

                            CV Carb rebuild tutorial
                            VM Carb rebuild tutorial
                            Bikecliff's website
                            The Stator Papers

                            "The thing about freedom - it's never free"

                            Comment


                              Originally posted by Shin-Ken 1074 View Post
                              OEM steel starter cover.


                              SZ OEM starter cover by Max Mutarn, on Flickr


                              Carbon cover and bolts.

                              Carbon cover and bolts by Max Mutarn, on Flickr


                              DW Carbon Cover by Max Mutarn, on Flickr





                              Running tally = 150,617 grams.

                              Thats pretty cool Do you think it's possible to mould engine and front sprocket covers the same way? More layers of course, but it would save alot of weight.

                              Comment


                                Originally posted by Lorenzo View Post
                                And they absorb some high pitched vibrations too
                                Yes, light weight and can help with absorbing vibration if needed.
                                Badgezz, we don need noh stinkin' badgezz!
                                Shin-Ken 1074
                                1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                                1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                                Comment

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