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1981 GSX1100 Katana Based Project

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    It didn't take (too) long for me to figure out that 'ally' meant alloy. Please remind me what "DW" stands for.
    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 Post
      It didn't take (too) long for me to figure out that 'ally' meant alloy. Please remind me what "DW" stands for.
      DW = Dry Weight.
      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

        DW = Dry Weight.
        I thought it was a Kawasaki dual sport. I was close.
        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

          I thought it was a Kawasaki dual sport. I was close.
          Yeah, close enough, they both start with a "K" so an easy one to mix up.

          Katana - Kawasaki
          Last edited by Shin-Ken 1074; 11-30-2023, 01:26 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


            Not much work done on the build for a few days, the only thing I have done is to make an aluminium number plate bracket but that is all. Side-stand should be back from the welder on Friday and then it can be tested, it should work.
            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


              Sidestand is back from the welder and even with the welding it is still half the weight of the OEM sidestand. Just needs a tidy up and some paint and its ready to go.

              DW sidestand by Max Mutarn, on Flickr
              Last edited by Shin-Ken 1074; 11-30-2023, 09:23 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


                Front guard is now on, the wheel and calipers have to be removed to install the guard as the 18" x 2.50 rim and 110 tyre leaves no room to fit the guard bolts. The gap between the tyre and fork leg is less than the length of the bolts, and they are short bolts.

                I am used to having a 19" 90 section front tyre and with that tyre there is enough space to get at the guard bolts and I hadn't thought about the wider tyre and rim before trying to fit the guard as usual. New lesson for me today.


                Front guard 1 by Max Mutarn, on Flickr

                Running tally = 172,180 grams.
                Last edited by Shin-Ken 1074; 12-02-2023, 12:37 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


                  Have replaced the OEM steel number plate bracket with a 0.5 mm aluminium bracket, much lighter. Waiting for primer and gloss black paint.


                  Number plate bracket 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.

                  Comment


                    The factory installed horn for a Kat is above the tappet cover in a pretty tight location however, now that there is an EF 1135 engine installed in the frame there is even less room for the horn in its usual position. I am not fitting the faux plastic oil cooler so I am going to move the horn to that position and see how that goes. Two advantages to the new horn location:

                    1) makes tappet cover removal easy with the horn out of the way

                    2) with the horn facing forward it might even be heard from 10 feet away, unlikely, they are pretty feeble at the best of times.



                    horn factory position by Max Mutarn, on Flickr


                    horn alternate position 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


                      The original plan was to fit a set of twin horns however, they are just to heavy! Back to the factory single for now.



                      twin horn 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


                        Check these, assertive and light.
                         
                        GS1000G '81

                        Comment


                          Originally posted by Lorenzo View Post
                          Check these, assertive and light.
                          Hi Lorenzo, thanks for the link to the FISA site. Much better volume than OEM horn however, they don't list the weight of any of the horn models on their site. I'll do some more digging and see if I can find the weights. The basic model will have to be lighter than the OEM single horn to make it a viable option.

                          OEM single 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


                            Side-stand painted and will be the next addition to the tally tomorrow. The M6 locking bolt isn't fitted in the pic, have yet to drill and tap the ally section for the locking bolt.

                            DW sidestand 3 by Max Mutarn, on Flickr


                            DW sidestand 2 by Max Mutarn, on Flickr


                            Last edited by Shin-Ken 1074; 12-02-2023, 06:30 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


                              It's from hidden parts that you see the care and the refinement puu into a project.
                              Last edited by Lorenzo; 12-03-2023, 06:45 AM.
                              GS1000G '81

                              Comment


                                The completed sidestand with a steel clevis and steel bolt, not Ti this time, I am running out of them.


                                OEM stand spring.

                                sidestand spring by Max Mutarn, on Flickr

                                OEM side stand

                                OEM side stand by Max Mutarn, on Flickr


                                DW side stand

                                DW sidestand a 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

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