1981 GSX1100 Katana Based Project

[Rob S.]

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

[Shin-Ken 1074]

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.

[Rob S.]

DW = Dry Weight.

I thought it was a Kawasaki dual sport. I was close.

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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.

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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.

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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

[Lorenzo]

Check these, assertive and light.

[Shin-Ken 1074]

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

[Shin-Ken 1074]

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

[Lorenzo]

It's from hidden parts that you see the care and the refinement puu into a project.

[Shin-Ken 1074]

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