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1981 GSX1100 Katana Based Project

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    Total exhaust system weight = 3,328 grams.


    Zorst 4 by Max Mutarn, on Flickr


    Zorst 7 by Max Mutarn, on Flickr




    Bracket trimmed to fit behind the footpeg mounting plate.
    bracket trimmed by Max Mutarn, on Flickr




    The yellow zinc finish on the bracket blends in well with the titanium pipe.

    Zorst 8 by Max Mutarn, on Flickr


    Zorst 6 by Max Mutarn, on Flickr





    Muffler fit is nice and tidy and hugs the swing-arm like it was designed for the build. I bought the muffler used and it had been damaged in a prang with road rash and cracked carbon at both ends of the can. Trimmed the carbon and reshaped the damaged titanium end caps and put it back together with aluminium rivets and straps.

    Zorst 5 by Max Mutarn, on Flickr


    Running tally = 182,995 grams.
    Last edited by Shin-Ken 1074; 12-08-2023, 05:13 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


      Will be fitting the cables over the weekend, fresh minty new ones. I am surprised they weigh this much, 636 grams is more than I expected, I had estimated they would be around 450 grams.

      Throttle cable.
      cable 1 by Max Mutarn, on Flickr


      Speedo cable.
      cable 2 by Max Mutarn, on Flickr


      Clutch cable.
      cable 3 by Max Mutarn, on Flickr
      Last edited by Shin-Ken 1074; 12-08-2023, 05:06 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


        Fuel tap and cables for the tally today.


        tap by Max Mutarn, on Flickr

        Running tally = 183,857grams.
        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


          Uuuummm....that muffler is gonna be loud!
          2@ \'78 GS1000

          Comment


            Originally posted by steve murdoch View Post
            Uuuummm....that muffler is gonna be loud!
            Repacked it with high density fibreglass packing, it will be nice and mellow, soothing even.
            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

              Repacked it with high density fibreglass packing, it will be nice and mellow, soothing even.
              A Million Little Fibers...

              You didn't give us the stats on the glass packing. Did you weigh it in one shot, or each strand individually?
              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

                A Million Little Fibers...

                You didn't give us the stats on the glass packing. Did you weigh it in one shot, or each strand individually?
                Oops, here ya go. Fibreglass packing (in one shot) and used micro mesh aluminium to keep it inside the can.


                packing by Max Mutarn, on Flickr


                micro mesh 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


                  Aluminium rear indicator brackets in Gloss Black.


                  indicator brackets 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


                    HEL brake lines installed today. Front brakes have a line each direct from the master to each caliper, light and easy to bleed.

                    DW front lines by Max Mutarn, on Flickr

                    3 x HEL lines = 300 grams.

                    3 x sets HEL banjo bolts and crush washers = 77 grams.


                    Running tally = 184,234 grams.

                    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


                      A combination of an aluminium cowl frame to replace the OEM steel frame and swapping the OEM headlight for a brighter, lighter headlight worked out pretty well weight wise. Here are a few pics that show the difference.


                      OEM headlight.

                      OEM a3 by Max Mutarn, on Flickr


                      DW headlight.

                      DW a4 by Max Mutarn, on Flickr


                      OEM headlight bracket

                      OEM a5 by Max Mutarn, on Flickr


                      DW headlight bracket

                      DW a5 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


                        Same thing for the tail light, swapped OEM unit for a lighter unit. The replacement tail light is brighter (a later design), and is lighter.

                        OEM tail light.

                        OEM tail light by Max Mutarn, on Flickr


                        DW tail light.

                        DW tail light 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


                          Most of these light parts are lots better looking too IMO. Nice work!
                          1986 1150EF
                          2008 GS1250SEA

                          Comment


                            If a may suggest a lile improvement on detracting from the weight tally:

                            Purchase the Superbike Rear Brake Reservior Kit from SportbikeTrackGear.com Get the lowest price, free shipping deal, easy exchanges and no restocking fees - Guaranteed!

                            Comment


                              Modified horn bracket is finished, went with silver so it blends in with the frame instead of the factory black.


                              H 1 by Max Mutarn, on Flickr

                              H 2 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


                                Aluminium rear indicator brackets are finished.


                                OEM indicator and bracket.

                                RI 2 by Max Mutarn, on Flickr



                                DW indicator and bracket.

                                RI 1 by Max Mutarn, on Flickr


                                RI 3 by Max Mutarn, on Flickr


                                RI 4 by Max Mutarn, on Flickr


                                Running tally = 184,704 grams.
                                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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