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1981 GSX1100 Katana Based Project
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Originally posted by Lorenzo View Post1982 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.
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Having a few spares bins can be very helpful to keep these vintage GSX Suzuki machines running, ya never know what part will come in handy at short notice. Like when working on a part and you discover two steel bolts on the rear caliper could be replaced with Ti bolts from the "Ti bolts spares bin", got lucky on that one.
Spares Bin 1 by Max Mutarn, on Flickr
Spares Bin 2 by Max Mutarn, on FlickrLast edited by Shin-Ken 1074; 02-23-2024, 01:30 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.
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Picked up the new pads today and now the rear caliper is back together at last. Tomorrow should have the overhauled rear caliper, new brake line and master cylinder installed.
OEM pads by Max Mutarn, on Flickr
Caliper 20 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.
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Installed the rear caliper and master cylinder today, bleed the system and it is working as advertised, could come in handy one day? Brakes, what a drag!
New pistons and seals fitted to the caliper, new pads installed and new overhaul kit fitted to the master cylinder along with a new brake line.
Rear brake 1 by Max Mutarn, on Flickr
Slow going topping up the master res 15ml at a time while bleeding the system.
Rear brake 2 by Max Mutarn, on Flickr
Rear brake 3 by Max Mutarn, on Flickr
System bleed and holding pressure when the brake is applied. So far so good!
Rear brake 4 by Max Mutarn, on Flickr
Caliper with its new titanium bolts from the "Ti bolts spares bin" to complete the rear brake system overhaul. Only two main jobs remaining, some final wiring to sort out and tune the carbs.
Rear brake 5 by Max Mutarn, on FlickrLast edited by Shin-Ken 1074; 02-25-2024, 06:03 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.
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Originally posted by Shin-Ken 1074 View PostCaliper with its new titanium bolts from the "Ti bolts spares bin" to complete the rear brake system overhaul. Only two main jobs remaining, some final wiring to sort out and tune the carbs.
Rear brake 5 by Max Mutarn, on Flickr
Nice way to solve that problem.---- Dave
Only a dog knows why a motorcyclist sticks his head out of a car window
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Yeah, I agree 100% with you about the older GS rear brakes being over engineered. Light weight modern brake systems prove just how light the brake components can be compared to the older parts.
The evolution of the rear rotor is a good example. An 1981 GSX 1100 OEM rotor weighing 2,145 grams compared to a 1986 GSXR 1100 and then to an aftermarket 1986 GSXR 1100 rotor weighing 533 grams, the aftermarket rotor = 75% lighter than the OEM rotor!
Rotors by Max Mutarn, on Flickr
The 1981 GSX 1100 OEM rear brake system;
rotor and bolts
torque brace and bolts
caliper/mount/bolts
brake line/banjos
master cylinder/res/bolts
brake pivot
brake pedal
total weight is 5,376 grams.
After swapping the OEM brake parts with modified and replacement parts the total weight for rear brake parts on this build is 2,592 grams, less than half the weight of the OEM system.Last edited by Shin-Ken 1074; 02-28-2024, 03:56 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.
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The plan is this weekend to finish up the wiring and then dial in the carbs. An engine builder I know well has advised me on initial main jet size to begin setting up the carbs. New jets should arrive this Friday. The engine has a few variables to contend with compared to a stock engine, it isn't a Hotrod but there are a few changes:
GSX1135 EF engine fitted with Yoshi profile hollow camshafts with a different lift to the stock EF camshafts, 750 F 36mm carbs with short velocity stacks - no airbox and a 4-1 exhaust system with a 58 mm I.D. pipe from the collector to the muffler outlet to help it breath!
To help dial in the carbs we are going to use an O2 sensor mounted in the pipe just forward of the muffler. A local muffler shop has welded a sensor bung into a sleeve they made to fit my titanium pipes, great work and did it on the spot in 15 minutes.
The sleeve with the O2 sensor bung is only fitted to the pipe when setting up the carbs and then removed once the carbs are sorted. Several of my friends have exhaust systems with the sensor bung welded in to the pipes and leave the bung in place however, I don't want to have the extra weight of the sleeve and sensor bung hanging off the system so it will be removed until needed for the next tune-up.
If all goes well I should have good news after the weekend.
O2 a by Max Mutarn, on Flickr
O2 b by Max Mutarn, on Flickr
O2 c by Max Mutarn, on Flickr
Ex 2 by Max Mutarn, on Flickr
Ex 1 by Max Mutarn, on FlickrLast edited by Shin-Ken 1074; 02-28-2024, 05:18 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.
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Originally posted by Big Block View Post02 sensor is the way to go. I've been tuning automotive carbs for decades. Finally bought an 02 setup and I can set dual carbs up in a matter of hours rather than a few days of trial and error.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.
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That looks like a nice, reasonably sized muffler. Hope you haven't got it jammed with heavy baffles and fiberglass.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.
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Originally posted by Rob S. View PostThat looks like a nice, reasonably sized muffler. Hope you haven't got it jammed with heavy baffles and fiberglass.
Can by Max Mutarn, on FlickrLast edited by Shin-Ken 1074; 02-29-2024, 01:01 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.
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Perfect! My kind of muffler.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.
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The replacement main jets arrived today and they have been installed. Carbs on, carbs off, carbs on, carbs off. Thankfully the build is not using the OEM airbox so its an easy job to remove carbs.
New Jet by Max Mutarn, on Flickr
Carbs have been re-installed, again, ready for the tune up this weekend. Fingers crossed!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.
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Took the Kat over to my mates place on the weekend to finish the wiring and some final checks on the carbs before starting the fine tuning with the 02 sensor. Tuning to be done later this week.
Carbs 01 by Max Mutarn, on Flickr
Wiring 1 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.
- Likes 1
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