92 GSXR 1127 engine into 750F Katana, [sick]

[Buffalo Bill]

Bummer, for the 1st time I tried taking a shim out. Easy to do because the rockers slide sideways out of the way.
Doh! Fumbled the tiny pill sized shim and it rolled down the oil return hole.
Looks like that's a quick return to the oil pan.
Now I gotta roll the 200lb lump over and take the pan off, just to fix a mistake.

Kids, be sure to stuff a wad into those return holes before you pull a shim out.

[kingofvenus]

Well, at least this way you'll see the lower internals condition before you put it in her new home....

[Fjbj40]

Can't get a magnet down there?

[Buffalo Bill]

Can't get a magnet down there?

Nice idea, but those oil passages channel through external to internal steel tubes, the magnet would cling to the first part of the tube.
Besides, kingofvenus is right, I need to have a look see of the engine bottom.

Couple things I don't like so far, the oil residue left in the engine feels rather used up, like it was overdue for an oil change.
Plus: the bike was scrapped because the PO broke the chain.

[Buffalo Bill]

OK, washed it out with waste oil from my car.
Dropped the oil pan, a tray with screen over it, below the oil galley. Pored waste oil down the drain holes and cam chain.
The shim showed up in the screen.

[dorkburger]

Good heavens, that thing is tiny. Where does that shim go? Im guessing a pocket in the spring retainer?
Im unfamiliar with the breed....

[gearhead13]

What are you doing for the clutch side on that 1127? Does the 750F cover fit so you can use the 750F cable clutch? Or are you going to get the hydraulic clutch setup?

[Buffalo Bill]

All the 1127s use a hydraulic clutch. I did not know that at the time but it makes sense to me.
I found a complete system with master cylinder, line and slave cylinder for $80, but the master cylinder needed a rebuild, another $30 for the kit.

My 82 GS1100G has a cable clutch, I replaced the plates and springs in it because they were slipping about 10%. Now it's a bear to squeeze.
The GS1100G only makes 66% of the power the 1127 makes, not even gonna think about using a cable clutch.

[stetracer]

in your pic it looks like the cams have a slight grove in the cams where the rockers ride. or is it just an optical elusion

[Buffalo Bill]

They seem to be highly polished there, the rest of the cam looks like it has a coating of some kind.

[Buffalo Bill]

Finding time to work on these projects, not easy

OK, this is the middle of the summer riding season, sure is hard to take a bike off the road for a project.
This is my track day bike, I need to have room between track days to build and tune this swap.

Here are all the big parts going into the bike:

[Buffalo Bill]

Painting this weekend…

OK, here's a last look at ye olde.
I've already wet sanded and prepped the body, and have it half taped.
I've decided to eliminate the aluminum side panels. Did NOT really want to toss OEM body parts, but Suzuki did it when they updated in '98.
I already got GSXR mirrors like 92xjunker has (katriders.com), those look real good, and they're genuine Suzuki with a slightly convex surface so I get a wider view behind, I love those.

[Buffalo Bill]

Here's a first look

OK more work to do, wet sand and 2nd clear coat, but here it is now.
PS: Those tape lines are sharp, they just don't look sharp online.

[dorkburger]

Looks good! A nice transformation for sure.

[Charlie G]

I looks really nice! Are you keeping the seat that color?

cg