1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

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.

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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

Carb boots by Max Mutarn, on Flickr

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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.

[Shin-Ken 1074]

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.

[Shin-Ken 1074]

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.

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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.

[Rich82GS750TZ]

That’s some slick fabricobbling, Max.

[Shin-Ken 1074]

Thanks Rich, fabricobbling is an art worth having.

Cheers.

[Shin-Ken 1074]

Carbs installed today.

Carbs 2 by Max Mutarn, on Flickr


Carbs 1 by Max Mutarn, on Flickr


Running tally = 156,909 grams

[Rob S.]

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

Can we assume that'll be a light beer?

[KiwiAlfa156]

Can we assume that'll be a light beer?

Not in Australia mate, you'd lose your citizenship.