1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

While I have a new OEM 630 sprocket on the table here is the difference in weight compared to the aluminium sprocket and titanium bolts.

OEM 630 sprocket, bolts and lock tabs = 1,924 grams.

Aluminium 520 sprocket and titanium bolts = 495 grams.

630 OEM 45T by Max Mutarn, on Flickr


630 OEM sprocket bolts by Max Mutarn, on Flickr

[Shin-Ken 1074]

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520 aluminium 48 T sprocket.

[Shin-Ken 1074]

Titanium bolt and aluminium nut x 5 = 125 grams.

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[Rob S.]

...make bar weights from round polymer, should weigh about the same as cotton candy?

Are you proficient with anti-matter?

[Shin-Ken 1074]

Yep, Anti-Matter and Dark Matter. Very difficult to find a supplier post COVID, Anti-Matter tube to make a frame would be top of the list.

[Shin-Ken 1074]

As our current weight loss champion,

Maybe the Kat could sign up as a "Weight Watchers" success story?

[Shin-Ken 1074]

Always a good day when parts arrive.

Throttle Cable a by Max Mutarn, on Flickr


Throttle Cable b by Max Mutarn, on Flickr

[John Kat]

My Kat Foreman wants to see a table of weight savings by descending order in order to guide future weight watchers in their quest to fly to the moon.

[Shin-Ken 1074]

My Kat Foreman wants to see a table of weight savings by descending order in order to guide future weight watchers in their quest to fly to the moon.

Watch this "Space" Kat Foreman.

[Shin-Ken 1074]

With the new throttle cables and a GSX-R1100 switchblock to match the twin cable throttle tube 2/3 of the job is done. The remaining 1/3 of the work is adapting the GSX-R 1100 switchblock wiring and harness connector as the harness connector blocks are different between the GSX-R and the stock SZ Kat. After swapping to a stock SZ Kat harness connector block and sorting out the wiring it should be good to go. That is a job for my mate the Electric Wizard.

GSX-R 1100 switchblock.

GSX-R 1100 block 1 by Max Mutarn, on Flickr


GSX-R 1100 harness.

GSX-R 1100 connector by Max Mutarn, on Flickr


GSX-R 1100 harness connector.

GSX-R 1100 connector 1 by Max Mutarn, on Flickr


GSX-R vs SZ wiring.

GSX-R vs SZ 2 by Max Mutarn, on Flickr

GSX-R 1100 vs SZ harness connector.

GSX-R vs SZ 1 by Max Mutarn, on Flickr

[Rob S.]

My Kat Foreman wants to see a table of weight savings by descending order in order to guide future weight watchers in their quest to fly to the moon.

I second that emotion.

[Shin-Ken 1074]

I second that emotion.

No problem, all the details have been listed here. Just follow the bouncing ball through the posts and you will be able to compile a list of parts and weights in your preferred order.

[Shin-Ken 1074]

New seals and pistons today.

Cleaned the pistons with acetone to remove any contamination from the manufacturing and packaging process before installing the pistons.

Caliper 1 by Max Mutarn, on Flickr


Caliper 2 by Max Mutarn, on Flickr

Wipe pistons dry and then let them sit for awhile to ensure all the acetone has evaporated before installing.

Installing new seals.

Caliper 3 by Max Mutarn, on Flickr


All four new seals installed.

Caliper 4 by Max Mutarn, on Flickr

[Shin-Ken 1074]

A very light film of brake fluid on the seals and pistons help the new pistons glide past the new seals with finger pressure.

Caliper 5 by Max Mutarn, on Flickr


Caliper 6 by Max Mutarn, on Flickr


Caliper 7 by Max Mutarn, on Flickr


Caliper 8 by Max Mutarn, on Flickr


Caliper 9 by Max Mutarn, on Flickr


Caliper 10 by Max Mutarn, on Flickr

[Shin-Ken 1074]

Used Red Rubber Grease for the slide pins and boots.


Caliper 11 by Max Mutarn, on Flickr


Caliper 13 by Max Mutarn, on Flickr


Used a pine rod to install the captive slide pin boot, makes it easy to install.

Caliper 14 by Max Mutarn, on Flickr

Caliper 15 by Max Mutarn, on Flickr


Slide pins ready to be installed.

Caliper 16a by Max Mutarn, on Flickr


Caliper 16b by Max Mutarn, on Flickr


One caliper done, rinse and repeat.

Caliper 16c by Max Mutarn, on Flickr


Caliper 17 by Max Mutarn, on Flickr