1981 GSX1100 Katana Based Project

[Rob S.]

What is a "rear guard"?

What is a "front guard"?

Are you talking about fenders, or mud guards?

[Shin-Ken 1074]

What is a "rear guard"?

What is a "front guard"?

Are you talking about fenders, or mud guards?

In Oz they are guards, short for "mud guards".

[Rich82GS750TZ]

For those following along, 50 kg = 110.23 lb.
This got me to wondering:
Why is pounds abbreviated as lb? So I had to look it up.
“Pounds” derives from the name of an ancient Roman unit of measurement, Libra pondo. This Latin phrase translates to “a pound by weight.” Our word “pound” comes from pondo, and its seemingly unrelated abbreviation, “lb,” comes from the libra part.

This all would be so much simpler if we had all gone all metric like our grade school teachers promised we would be by the time we reached adulthood. I wonder if teachers in the US are still telling that fib to the kids.

Sorry to derail this thread. Please carry on. Following with interest.

Ok, back to the program. And I will reiterate-

image.jpg

[Shin-Ken 1074]

Hi Folks, the DW 180 weight reduction today is 682 grams.

Remove set of steel exhaust flange clamps = 438 g. Replace with aluminium flange clamps = 161 g.

Remove OEM cam chain tension adjuster = 401 g. Replace with aftermarket aluminium manual cam chain tensioner = 86g.

Remove OEM fork spring pre-load adjusters = 216 g. Replace with aftermarket aluminium pre-load adjusters = 126 g.

Tomorrow I'll weigh the exhaust flange steel bolts and the replacement Titanium exhaust bolts as well as the OEM steel engine mounts and the replacement aluminium engine mounts.

Cheers.

[slayer61]

For those following along, 50 kg = 110.23 lb.
This got me to wondering:
Why is pounds abbreviated as lb? So I had to look it up.
“Pounds” derives from the name of an ancient Roman unit of measurement, Libra pondo. This Latin phrase translates to “a pound by weight.” Our word “pound” comes from pondo, and its seemingly unrelated abbreviation, “lb,” comes from the libra part.

This all would be so much simpler if we had all gone all metric like our grade school teachers promised we would be by the time we reached adulthood. I wonder if teachers in the US are still telling that fib to the kids.

Sorry to derail this thread. Please carry on. Following with interest.

Ok, back to the program. And I will reiterate-

image.jpg

Ya. 3 pages so far and Ian is the only one to add a pic...

[Rijko]

Hi Folks, the DW 180 weight reduction today is 682 grams.

Remove set of steel exhaust flange clamps = 438 g. Replace with aluminium flange clamps = 161 g.

Remove OEM cam chain tension adjuster = 401 g. Replace with aftermarket aluminium manual cam chain tensioner = 86g.

Remove OEM fork spring pre-load adjusters = 216 g. Replace with aftermarket aluminium pre-load adjusters = 126 g.

Tomorrow I'll weight the exhaust flange steel bolts and the replacement Titanium exhaust bolts as well as the OEM steel engine mounts and the replacement aluminium engine mounts.

Cheers.

I LIKE you post the solutions and weight savings Ken, thank you.
Your last post makes it clear again that many smaller savings do add up.
For me, this thread is getting more interesting with every post you make, it's gonna be a favorite.

Thanks again !

[Suzukian]

This all would be so much simpler if we had all gone all metric like our grade school teachers promised we would be by the time we reached adulthood. I wonder if teachers in the US are still telling that fib to the kids.

Having a young son who just went through the whole system, I can say for my town, they do not teach abut a "Metric Future", they teach you should know both systems.

All those little weight savings do add up, and inevitably make for a very interesting motorcycle.

[Shin-Ken 1074]

Hi Folks, today its the engine mount plates and header bolts.

OEM steel engine mount plate set, no bolts only plates = 837 grams

Complete set of OEM steel engine mounting bolts = 938 grams. Some of those will be swapped for titanium, not the long bolts - very expensive.

Eight steel header flange bolts = 200grams

Eight Ti tapered allen header flange bolts = 72 grams.

Using a mix of OEM steel and Ti bolts there are a few grams to be shaved here. Will know exactly once the engine is bolted into the frame in a couple of days time.

Have decided on a photo hosting service so in the next few days images will be posted, if all goes well? Painted frame, engine, side covers, cowl, seat, guard etc, look good in their new paint.

Cheers,
Glen.

[Shin-Ken 1074]

Hi Folks, weather has been damp and cold the last few days so painting the engine mounts has been delayed. Was hoping to have the engine in the frame this weekend and measure up for the aluminium rear axle spacers and off - set for the front sprocket if needed. Gives me time to order a few new parts from Suzuki so not a total loss.

Cheers.

[Shin-Ken 1074]

Hi Folks, having great difficulty trying to work out how to post images on the Forum from my phone using XnViewMP. So for today it is text update only.

1985 GSX1135 EF engine was installed into the 1981 Kat frame today, all good. Used a combination of OEM and titanium bolts along with OEM steel engine mounts. Did a bit of tweeking to the frame on Tuesday and it is now 17,984 grams bare but painted.

Engine went in missing a few parts to make it easier to fit: no oil,no oil filter cover, no tappet cover, no clutch cover, no sprocket case, no carbs, no starter motor, no sprocket.

It did have a set of Yoshi hollow cam shafts fitted, much easier to install when the engine is out of the frame.

1985 GSX1135 EF OEM cam shaft weight: Ex = 1,532g IN = 1,525g.

Yoshi Suzuki GSX 1100 hollow cam shaft weight: EX = 1314g IN = 1331g

OEM cams = 3,057g vs hollow cams at 2,645g.

So in its minimalist form the engine came in at 77,750 grams. Engine weight will increase as the parts that were removed to help with installing it in the frame are fitted. Several of these parts have been modified so there will be an OEM v DW180 parts weight comparison.

OEM steel engine mount plates with OEM and Titanium bolts total = 1,272g.

So at this stage the project with frame and most of the engine weighs 96,006 grams sitting on the bench. From today each post will end with the weight of the project for the day.

Cheers.

[Shin-Ken 1074]

Hi Folks,

Have spent the last few days planning the rear brakes before installing the swingarm. Going to use a 2005 GSXR 1000 caliper married to the stock 1982 Kat swingarm so a few mods are needed to make it work. Having an aluminium bush made to reduce the K5 caliper mount axle diameter down to 20mm to match the Katana axle size. Being an underslung caliper it will need a torque brace installed below the swinger so I'll make the brace from aluminium round tube with rose joints fitted at each end and a bracket welded to the swinger to house the forward rose joint.

The reason for going with the K5 caliper is weight, or to be accurate, less weight. The stock SZ Kat rear caliper is 1,415 grams compared to the K5 caliper at 814 grams, 601 grams off the caliper is heading in the right direction for the project. Ti bolts will also help.

Once the caliper mount has been sorted, the wheel can be installed and positioned for the chain alignment. With the wheel in place and measurements taken, next will be having the axle spacers made from alumimium.

I have adapted a set of Yamaha R1 aluminium axle holders and made a pair of aluminium chain adjuster blocks to suit. Total weight of the two chain adjusters is 184 grams less than the stock 1982 steel chain adjusters including Ti bolts of course.

With nothing added to the frame there is no change in project weight so it is still at 96,006 grams on the bench.

Cheers.

[Shin-Ken 1074]

Hi Folks, the 2005 GSXR 1000 caliper bracket now has a bush fitted to suit the 20 mm Kat axle. The K5 caliper fits snug with a few mm's to spare so now I just have to plan the position of the forward torque brace mount, keeping it in the same plane as the brake rotor. For the torque brace I'll use 16 mm aluminium round and tap each end to fit 8mm rose joints. Once everything is in place the swing arm will be sent to have the forward torque bracket welded to the swingarm. The same place that does the ally welding will also be making the new ally axle spacers. Should have it back by the end of next week. Then it is wheels on and starting to look like a bike at last.

cheers.

P.S. The two options to mount the caliper torque brace position:

1) Mount the forward torque brace towards the pivot area of the swinger

2) Mount the torque brace to the frame.

Cheers

[Shin-Ken 1074]

Hi Folks,

A bright new day and a new idea for the caliper torque brace. Adapt the K5 caliper mount incorporating an adjustable slide to allow for chain adjustment and repositioning of the caliper mount. This option has some attractive advantages:

a) light weight - much lighter than 2 rose joints and a length of 16mm ally round and a forward bracket
b) will not be affected by pipes/muffler
c) will have a factory look rather than a cobbled together solution
d) would only require a small tab to be welded to the underside of the swinger and one bolt with a locknut

At this stage I am keen to go with this option.

Cheers.

[Shin-Ken 1074]

Hi Folks,

Fitted the rear wheel today to measure for axle spacers and where the rear brake caliper mount position will be on the swing arm. Should have the details sorted by tomorrow and then swingarm off the Kat and down to the welder to weld the caliper tab and make the axle spacers.

Once all that is done and parts test fitted to ensure all is well, remove it all and send ally parts to be anodized before final installation, and weighing.

Cheers.

[Shin-Ken 1074]

Hi Folks,

The DW180 will be using 1985 GSXR 750 wheels, I have the wheels but did not have the rotor side and sprocket side spacers for the rear wheel axle seals. I ordered the two OEM spacers last week however, they haven't arrived yet. I need these as a template for the engineering crew to machine up the spacers in aluminium. Spacers wont arrive until Thursday so a bit of a delay on the spacer front. Will make a start on fabricating the rear caliper mount so it is ready by the time the OEM spacers arrive.

Cheers.