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1981 GSX1100 Katana Based Project

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    Originally posted by Diirk View Post
    I'm thoroughly excited to see the end result, but at the same time I'm not in a hurry to see it either because I'm enjoying the process
    Those Nitron shocks look the mutt's nuts btw.
    Yeah, I am looking forward to how the Nitron shocks perform on the DW. The shocks are made in the U.K. and the DW 180 specs were provided so the shocks could be built with valves and springs to suit the DW. Ordered, built, shipped and delivered in two weeks to the other side of the world, that is great customer support in my book.
    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


      Plan A was to use OEM front calipers however, that has changed and now later model Suzi twin-pot calipers that offer better performance are lighter than OEM and all the parts are available so these can be maintained for many years to come.

      Plan B is to use 2004 GSX 750 front calipers, some fine tuning is needed to get the calipers lining up true with the rotors and mounting brackets will need to be made because the 2004 caliper mounts are a different pitch to OEM SZ calipers.

      The rightside outer wheel spacer needed a bit of a trim, file and wet sanding has it to the correct size now. Not a big problem considering the calipers are now being changed from the original plan and the Slabbie front wheel was turned down on a manual lathe to fit the Kat forks. It is a miracle the front spacers were only out by 1.75 mm after the change in plan.

      2004 caliper, twin piston, larger pads and lighter than OEM.


      2004 GSX 750 caliper by Max Mutarn, on Flickr


      spacer 1 by Max Mutarn, on Flickr


      Spacer 2 by Max Mutarn, on Flickr



      Spacer 3 by Max Mutarn, on Flickr




      Spacer 5 by Max Mutarn, on Flickr



      Spacer 6 by Max Mutarn, on Flickr
      Last edited by Shin-Ken 1074; 11-09-2023, 07:55 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


        New carb boots have arrived so carbs on today as well as a few other parts.

        Carb boots 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


          As a percentage of weight saved replacing the OEM auto cam chain tension unit with a manual unit is a winner.

          OEM cam chain tensioner by Max Mutarn, on Flickr


          DW cam chain tension manual 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


            Cam chain with manual tension unit fitted, before setting chain tension.

            Cam Chain 1 by Max Mutarn, on Flickr


            Tension set with manual cam chain unit.


            Cam chain 2 by Max Mutarn, on Flickr


            Cam chain run-out checked, all good.

            Cam chain 3 by Max Mutarn, on Flickr

            Manual cam tension unit installed.


            Cam chain 4 by Max Mutarn, on Flickr




            Running tally = 153,275 grams.

            Last edited by Shin-Ken 1074; 11-09-2023, 10:03 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


              Aluminium battery cradle and Ti bolts ready to go.

              Ally cradle 1 by Max Mutarn, on Flickr

              Ally cradle 2 by Max Mutarn, on Flickr




              Running tally = 153,534 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


                OEM oil pressure sensor and Ti bolts.


                Oil press sensor 1 by Max Mutarn, on Flickr


                Oil press sensor 2 by Max Mutarn, on Flickr


                Running tally = 153,649 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


                  Before installing the carbs they need a manual choke to be fitted. There is some damage to the carb fittings so I will have to work with what I have. Found an old manual door lock knob off a vehicle from who knows what in the box of things you never throw away. I think I can get this to work.

                  door lock 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


                    First thing is to file away some material to allow the lock rod to fit the carb mount, the one that isn't broken.

                    choke 1 by Max Mutarn, on Flickr


                    choke 2 by Max Mutarn, on Flickr


                    choke 3 by Max Mutarn, on Flickr


                    The choke rod fits, now to work out how to secure it to the choke bar where the original choke cable would have been attached.


                    choke 4 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


                      Shaped the end of the rod into an eye and then filed it flat to fit inside the original choke cable holder. M4 bolt and locknut to secure the rod in the cable holder. New choke works smoothly with full range of movement for the choke rail. I installed the manual choke on the left side of the carbs so the choke can be used with the left hand while the starter button and throttle are operated as usual.

                      Choke 6 by Max Mutarn, on Flickr


                      Choke 7 by Max Mutarn, on Flickr


                      Choke 8 by Max Mutarn, on Flickr


                      Choke 9 by Max Mutarn, on Flickr


                      That is all for today, its cold beer time now.
                      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


                        That’s some slick fabricobbling, Max.
                        Rich
                        1982 GS 750TZ
                        2015 Triumph Tiger 1200

                        BikeCliff's / Charging System Sorted / Posting Pics
                        Destroy-Rebuild 750T/ Destroy-Rebuild part deux

                        Comment


                          Thanks Rich, fabricobbling is an art worth having.

                          Cheers.
                          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


                            Carbs installed today.

                            Carbs 2 by Max Mutarn, on Flickr


                            Carbs 1 by Max Mutarn, on Flickr


                            Running tally = 156,909 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


                              Originally posted by Shin-Ken 1074 View Post
                              That is all for today, its cold beer time now.
                              Can we assume that'll be a light beer?

                              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 Rob S. View Post

                                Can we assume that'll be a light beer?
                                Not in Australia mate, you'd lose your citizenship.


                                "Johnny the boy has done it again... This time its a scrubber"
                                Dazza from Kiwiland
                                GSX1100SXZ, GSX750SZ, GS650GZ All Katanas, all 1982

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