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

[Buffalo Bill]

Hey thanks!
Charlie, whatsa matta with that color?

[Charlie G]

Well, I really didn't mean to imply there was anything wrong with the color. Just wondering.........

[Buffalo Bill]

Well, it seems to blend well with the maroon.
Originally I chose that color because it resembles tan leather.
I considered deer hide and that's much nicer, but it ain't waterproof.

[Buffalo Bill]

assembled

OK, I was able to finish the clear coat, and assembled the bike. I'll ride it for a couple weeks, then all the important panels will need to be wet sanded and buff polished.

[Buffalo Bill]

Some personal maintenance issues are catching up with me: sore molar that may need to be chiseled out, cat is coughing weird, my car is dripping trans fluid, and I have a summer cold.
However, I did replace 3 tappet shims and assembled the clutch master cylinder tonight.

Seems that these Suzuki clutch master cylinders have an issue, people say the clutch hangs up (?) I think that means they don't push the clutch rod in quite far enough.

Looks like I have time to swap in the 1127 this month.

[Buffalo Bill]

Back to my project

Well I was too busy or too tired to do any work on the bike all summer. Spent my weekends just napping on the couch with the cats.
However I did buy some better gear for track riding, and get on the road practicing my cornering skills.
Did the last track day of the season on 10/23/15, so now I'm preparing to do the engine swap.
Gonna do some suspension upgrades too.
Just bought a GSXR rear wheel; 5.5" wide so I can use a 180/55-17 tire, and new fork springs from Sonic Springs.
Thinking about buying a rear shock from a Yamaha YZF-R6, they bolt right in. However the original shock seems to work fine.

[Buffalo Bill]

Wheel swap-mo bigga, mo betta

Wow, what a size diff; 160 to 190.
But I'm only gonna go 180, an that's about all that's gonna fin in theah.

[Buffalo Bill]

This is the weekend

Getting started Saturday:


Break time


Looks like the wheel and fender need to come off, then the front end tilted up and off the engine.
Maybe the forks too.

[Buffalo Bill]

Bolted in there, but…

Well I got it bolted in there, but there is a clearance issue that needs some fabrication to solve.
The 1127 cylinder head is about 17mm taller than the 750. I had to take the breather cap off to clear the frame.
I need those 15mm cleared away, or at least 10mm. I'll probably have to mod the breather cap and the frame.

[Buffalo Bill]

Clearance issues

Ok, over at katriders.com the word is; just notch the frame members, and weld a plate over the notch to regain some of the strength.
Here's some closeups of the clearance issue, so you can see.
Frame clearance, I'm planning on notching it at that horizontal shadow in the middle.
The tank support, I'll cut away the notch about midway through the tube.
I'll weld a cut to fit plate on both those cuts to regain some of the strength, keep them from flexing. Although they seem to be more than the bike needs.

[dorkburger]

Well, thats cozy..... Yikes

[Buffalo Bill]

Ok, crude but this is my 1st weld job.


Mo-betta

[posplayr]

It is not the weld that would worry me. Can't you make that part any stiffer?

[Buffalo Bill]

Well, the only weight it carries is the gas tank.
I think it could support my static weight (180lb) in the center, much more on the tank pads.

[kingofvenus]

My son's '90 600 hasn't had that stupid center support on it for years. I think the front and rear mounts are more than sturdy enough. Those bikes need as much weight removed as possible.