1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

Comparing OEM headlight and cowl frame to DW headlight and ally cowl frame.

OEM headlight and frame by Max Mutarn, on Flickr


DW headlight by Max Mutarn, on Flickr


DW headlight subframe by Max Mutarn, on Flickr


DW headlight frame by Max Mutarn, on Flickr


OEM assembly = 2,370g vs 1,257 g for the DW assembly.

[steve murdoch]

Hi Lorenzo, what are Roadriders?

Are the tires Avon Roadrider Mark 2?

[Shin-Ken 1074]

Are the tires Avon Roadrider Mark 2?

Thanks Steve, got it now. For the project I went with Bridgestone Battlax T32 Radial tyres. Lightest radial tyre I could find for an 18" x 2.50 front and 18" x 3.50 rear that has good performance in wet and dry conditions.


Bridgestone Radial by Max Mutarn, on Flickr

[Shin-Ken 1074]

Cowl, frame and headlight fitted.


OEM cowl by Max Mutarn, on Flickr


Running tally = 171,668 grams.

[Shin-Ken 1074]

A milestone event today, the Kat is off the bench and on her wheels for the first time at the start of her new life. Had three friends help lift her off the bench and to make it easier to lift, the rear guard and cowl were removed so we could grab the frame and forks and not damage anything. Wow, a great feeling seeing her on the deck at last, still smiling!

23 Nov 23 on wheels 1 by Max Mutarn, on Flickr


23 Nov 23 on wheels 2 by Max Mutarn, on Flickr

[Shin-Ken 1074]

Tomorrow taking her out for the day to have new HEL brake lines made and fitted. Now that she is off the bench and not resting on the OEM sump I can replace the OEM sump with a modified and lighter sump which means the running tally will be reduced, happy times!

The modified sump.
DW sump by Max Mutarn, on Flickr

[Lorenzo]

Had three friends help lift her off the bench and to make it easier to lift, the rear guard and cowl were removed so we could grab the frame and forks and not damage anything.

Eerr It shouldn't have been that bad after all the effort put in before...

[Rob S.]

Yes, with all that weight shaved and saved, I'd have thought you could have done it single handed.

Remind us, is she close to about 400 lbs?

[Shin-Ken 1074]

Eerr It shouldn't have been that bad after all the effort put in before...

We had been drinking Rum for the afternoon so four bodies to lift her down seemed like a good idea, that way if we dropped her she would fall on someone and not damage the new paint.

[Shin-Ken 1074]

Yes, with all that weight shaved and saved, I'd have thought you could have done it single handed.

Remind us, is she close to about 400 lbs?

Err, yeah,nar, enjoying a few Rums and relaxing, talking bikes with the crew and then the light bulb flashed on, while the bodies are here let's lift her off the bench. Job done and back to the drinks.

Weight wise as of yesterday = 379 lbs.

[Shin-Ken 1074]

If it's Friday it must be brake line day. Had these made today at the local HEL agent.

HEL lines 1 by Max Mutarn, on Flickr


HEL lines 2 by Max Mutarn, on Flickr


HEL line 3 by Max Mutarn, on Flickr

[Shin-Ken 1074]

The OEM side stand is drop forged steel and weighs close to 900 grams so I have been thinking about a lighter version. The lizard brain in me tells me that as sexy as aluminium is to reduce weight, the stress on an aluminium side-stand clevis for an "Old School" street bike raises a concern. The idea of using a steel clevis is lowering my heart rate so I'll start there. Found an old Suzuki dirt bike side-stand in the parts bin, going by the blue colour most likely a mid 1980's model?

Cut it down and reversed it so the spring retaining pin is positioned to the outside to mimic the OEM Kat pin position. Filed the clevis to fit the Kat side-stand lug and then cut a notch in the steel to make an angle. Next was to use some ally round tube to fit inside the steel section, this will be held in place with a bolt on the inside of the side-stand.

Sidestand 11 by Max Mutarn, on Flickr


Sidestand 1 by Max Mutarn, on Flickr


Then cut and shape the footplate
Sidestand 2 by Max Mutarn, on Flickr


An aluminium footplate will wear out pretty quickly so to get around that issue I will fit a sacrificial plate to the bottom of the footplate, it wears out and is replaced when needed.
Sidestand 3 by Max Mutarn, on Flickr


Sidestand 6 by Max Mutarn, on Flickr

[Shin-Ken 1074]

The ally round tube slides inside the steel clevis section and as a bonus this allows the side-stand to be adjustable, winner winner chicken dinner! Using the MK I eyeball to gauge the angle and length for the ally tube and then cutting it to size. Test fitting it to check for angles, seems O.K. Monday I'll drop it in to the welder to weld up the notch in the steel and TIG the round tube to the footplate.


Sidestand 7 by Max Mutarn, on Flickr


Sidestand 9 by Max Mutarn, on Flickr


Sidestand 10 by Max Mutarn, on Flickr


Sidestand 12 by Max Mutarn, on Flickr


Sidestand 13 by Max Mutarn, on Flickr

[Shin-Ken 1074]

Half the weight of the OEM side-stand.

Sidestand 14 by Max Mutarn, on Flickr

[Lorenzo]

Lovely-jobly; I reckon you could claim another win-win implement, by cutting a series of diamond patterns (doable with a triangular file) on the contact part of the sidestand; that will let you skim some more alloy, and guarantee a better grip on those icy days, so frequent down-uder ya know...?