1983 Katana 1100 GSXR conversion

[gs1000racer]

You are on your way. Have fun. El G.

Thanks! I already am! I also looked at the pics of your Kat. Pretty neat! What wheels are you running? Are those Buell?

Progress Notes:
I just managed to drill out the stupid phillips screws that keep the left side engine/sprocket cover on. They were all rounded out, so the drill was the only option. After the cover popped off, the screws just came right out. Now to find some nice stainless allen-head bolts.

After that, I pulled the last engine mount bolt and now the motor is ready to come out. I will post pics tonight or tomorrow.

I also cleaned up the front calipers and rotors and the look shiny and new!

Anyway pics to come of the work thus far...

[gs1000racer]

Progress notes:

Here are my shiny nice Busa calipers!



Found some really clean GSXR rotors for 60 bones. Basically new with some shelf wear.



This came out of my engine. The oil looked absolutely NASTY!!

[Smokinapankake]

Looks like some red overspray on the jugs?

Keep at it; you're on your way!

[GateKeeper]

Looks like some red overspray on the jugs?

Keep at it; you're on your way!

probably when the PO did the paint on the cover, not taking it off and probably not masking very well, to prevent the over spray....

[gs1000racer]

probably when the PO did the paint on the cover, not taking it off and probably not masking very well, to prevent the over spray....

Actually, the paint is only on the engine cover. It looks like it is not the original piece.

Progress notes:

I got the last of the motor mounts out, and now to get that stinking heavy motor out of the frame.

Any ideas? I don't want to wreck the engine covers if I can help it...

Thanks!

[mindtrip]

lookin good so far! I'll be following a long as you build!

[saffa]

lose the front and rear ends.........lay the frame and motor down on its side on carefully on something soft ...rotor cover first. then just remove mounts and maneuver frame off the motor. saves a busted back and knuckles

[GateKeeper]

if it's frame and engine only, tip the bike on it right side and lift frame, engine will stay on the ground.

if not, you will need two persons to wrangle it out, they are heavy, so be careful...



EDIT - saffa beat me to it.....

[hampshirehog]

Or....
Trolley jack under the sump (block of wood to protect the alloy), remove all the brackets lift a small amount and pull the jack out to the RH side. Once 1/3 of the engine is out tilt it on to a block of wood the same height as the lower frame rails and wriggle it out the rest. You have to lift maybe 30lbs rather than 200 plus if you just hoick it out.

Removing the breather cover gives you an extra few millimetres of clearance that help a lot.

This (in reverse) works well for putting the engine back in - just wrap the frame up in cardboard and tape to prevent scratches.

[mike-s]

The clutch basket on that thing appears novelty clown shoes huge compared to the rest of the engine in that pic.

But still $60 is nothing to sneeze at.

[Billy Ricks]

The clutch basket on that thing appears novelty clown shoes huge compared to the rest of the engine in that pic.

But still $60 is nothing to sneeze at.

Haven't seen any pictures of the basket as far as I can tell. I think you're referring the alternator rotor on the left side of the engine.

[gs1000racer]

Progress Notes:

Finally got the engine out of the frame without too much drama. I gently laid the bike down on it's right side, removed all the engine mounts and used a car jack to get the underside of the frame as high as possible (not very clear, i know). I then placed some jack stands under the frame to support it and used the car jack to raise the other side of the frame. As I did this, the motor pretty much just stayed on the ground as the frame went up. Voila!



I managed to remove the swingarm and remove the bearings (I destroyed them as I did this. Guess this work calls for new bearings, anyway.). I am having the swingarm painted, so the bearings needed to come out.



I removed the front end and gave the races one try for removal. No luck. Not sure how to get them out without scoring the frame surface. Any ideas about how to remove the bearing races?



Here is the front end. Everything is for sale and is in very good shape (other than the poorly painted wheel.



The frame is almost ready to go get blasted and powdered. Woohoo! (Yes, my garage is a disaster, so no cracks.)



I got this set of Metzler M1 sport touring tires for $20.00, no joke. Yay for good deals.



I forgot to post them earlier, but here is what the bike looked like when I first bought it.

[gs1000racer]

By the way, does anyone know if the Bandit 600 swingarm will work on this conversion? I can get those for a lot less money than the 1200. I know I can get a 1200 for not too much, but I would like to know anyway.

Thanks!

[gs1000racer]

Hi all,

It's been a while since I posted, but here has what the latest progress is:

I got the front and rear wheels stripped down, had the bearings pulled to get them ready for black powdercoat. The rear brake rotor bolts were a total bear to get out, since they have never come out since they were first installed. I got 4 out of 5 out and the last bolt rounded out. Go figure.

So, I had to use the handy bolt extractor with an impact gun and it finally came out. I think I'm gonna use some anti-seize on the new bolts.

I ground off some unnecessary bits from the frame and took to be braced and then powdercoated black. I should see results by late next week.

After they come back, it's time to mount all the suspension bits and get ready for engine work.

I'm thinking of bumping displacement to a healthy 1500cc's. We shall see!

Cheers,

[saffa]

bandit 6 will probably work but you'll end up with a thinner wheel than you can with the bandit 12 ...plus its steel not alloy which would suck.

also with regards to the 1500 idea ...dont. i did that ...great fun but get hot real quick if you end up in a bit of slow traffic and like to sweat oil too. i always came back with a wet foot which was ass. 1500 is great if you racing in short passes but 1170 is much more useable on the street.

just my 5 cents