1984 Katana 7/11

[Fjbj40]

Looking pretty damn sharp Pete

[pete]

Cheers Daryl!

Wish I had more progress to report but nothing at the moment, although I need to order at least the head nuts from Partzilla as soon as I'm paid at the end of the week. Taxes are changing here for international purchases, so I won't be surprised if a lot of companies stop selling to Australia to avoid a lot of paperwork.

[pete]

Not much in the way of progress lately, but I've started repairing the ignition cover at least.

This is how it started, cracked enough it didn't sit quite flush.

Untitled by starpoint73, on Flickr

I had a go at bending it but it was a bit too much, but that's made it a bit easier to get back in shape I reckon.

Untitled by starpoint73, on Flickr

JB Weld to the rescue again, still have one more piece to add in there yet.

Untitled by starpoint73, on Flickr

Sits much better now, just need to add the last missing piece and fill the other gaps with JB Weld.

Untitled by starpoint73, on Flickr

My piston rings arrived this week too.

Untitled by starpoint73, on Flickr

I also finished dismantling the head so I can start getting it ready for paint. Got all the rocker arms bagged and tagged.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

I'll try to pick a hone up this week so I can get the honing done, then I can start prep'ing the barrel and head for paint. Not too far away from getting the top end together once that's done, and then the motor can go in the frame at last.

[Sam 78 GS750]

Looks like you're hitting the home stretch here, Pete. What's left on the to do list once the engine's back in the frame?

[nvr2old]

Truly above and beyond to save an ignition cover, Pete. JB Weld is an amazing product that allows that kind of repair. Smoothed out and painted black, no one will know the difference. Getting the engine done will be just as much a jump as finishing the paint. It's going to be very satisfying.

[zuluwiz]

Cheers Pete. Good to see you making progress. I think we're all going to be waiting to hear about the First Ride.

[pete]

Cheers guys!

I've hit a point where I have time to work on stuff but no $$ to spend, so things like fixing that ignition cover are helpful to keep me occupied. And Larry, yep, love the JB Weld

As for what's left after the motor's assembled, well there's still a bit to do (this is not everything, just the big bits):

Finish and wrap the harness
Assemble brakes
Exhaust
Acewell gauge
Tyres
Chain and sprockets
Import compliance and registration

Not a long list but aside from the first two items where I have everything ready to go, the other 5 add up to a lot of $$ I'm going to have to wait to build up to month by month, so there's no way it will finish this year unfortunately, and I suspect it's going to be a few months in to next year at least, more than likely a bit longer as I put stuff together and find other things I'm missing.

Bit of a bummer when I'm so close to done but that's the way the cookie crumbles. I could save a few hundred and get it on the road with the tyres that are on there as they're perfectly legal, however they are old... one's 2003 and the other 2007, and I'm just not comfortable riding on tyres that old, especially on my dream bike I will have just finished and will be learning how it handles etc.

[Sam 78 GS750]

Cheers guys!

Not a long list but aside from the first two items where I have everything ready to go, the other 5 add up to a lot of $$ I'm going to have to wait to build up to month by month, so there's no way it will finish this year unfortunately, and I suspect it's going to be a few months in to next year at least, more than likely a bit longer as I put stuff together and find other things I'm missing.

Bit of a bummer when I'm so close to done but that's the way the cookie crumbles. I could save a few hundred and get it on the road with the tyres that are on there as they're perfectly legal, however they are old... one's 2003 and the other 2007, and I'm just not comfortable riding on tyres that old, especially on my dream bike I will have just finished and will be learning how it handles etc.

I hear you Pete... My list is short now too, but still looking to take some time. Disappointing... A few posts back when I mentioned how I started with the engine after getting a rolling chassis, and you started with paint, etc. you said when you did it that way on your 450, you were tempted to cut corners towards the end.

I definitely get what you mean now. I'm sooooo tempted to just slap the rest back together just to get it on the road and "get to that stuff later" but I know later would prob never come... As it is, I already put the cam chain tensioner back on all ugly. After a cleanup and o-ring replacement, but ugly lol. "No one's ever gonna see it..." but I'll know it's there.

Your wiring shouldn't be too expensive, but tires and exhaust there's no getting around the expense (and cheap isn't worth it). You've done amazing work so far, and the final result is gonna be a head turner and a blast to ride for sure!

[pete]

Yep Sam, it's easy to do! Still kicking myself for it on the 450 but she'll get some love whenever I finally get the Kat done. The wiring's not really going to cost any more, it's all but done except for the connections for the Acewell, and that's the only reason I haven't wrapped it yet. I have some self amalgamating tape here ready to wrap it.

I also hit a bit of a setback yesterday. I thought I'd checked and cleared the valve guides as good to go, but I must've been drunk. They're stuffed. I can wiggle the valves a good mm or so, don't even need to break out the dial gauge to see that level of movement. That's a bit over $300 for new guides and circlips. I need to break out the micrometer and check the valve stem diameters to make sure it's just the guides that need replacing rather than the valves as well.


I guess I could put it together as is, although I'm not too sure what the results of that would be other than allowing them to move and wear the seats a bit quick. If that's all, then I could potentially do that and put some cash aside for a proper top end rebuild down the track.

[pete]

Just ran through the valves with the micrometer, and yeah new valves and new guides are what's needed.

Exhaust valves spec is 0.2144 to 0.2150" (what my micrometer is in), and they're all just shy of 0.2144. It's only got a resolution of 0.001" but none of them are approaching the half way mark between 0.2140 and 0.2150, so definitely no good.

Inlet valve spec is 0.2150 to 0.2156" and not one of them is over 0.2150 and in fact a couple are closer to 0.2140 so they're also definitely no good.

The guides in there have been modified by the DIY porting job as well, so best just do it all right.

Might be worth a call to the guy who did the crank as he does APE stuff along with the Cometic gaskets etc., so he might be able to do good quality after market at a bit better price than genuine Suzuki. Certainly can't hurt to ask. I'd imagine he can cut the seats as well.

[Sam 78 GS750]

Bummer on the bad guides, Pete. The added expense/time has to sting this close to finishing the bike...

[pete]

Certainly is a bummer Sam, and looking at genuine parts for the guides, circlips, valves, and stem seals is over $1000 so it's a huge hit.

However, a mate may have me sorted yet as he has a spare head. If that works out I'll be in a better position than I was as it'll just need paint and I'll likely replace the valve stem seals if it's been sitting for a bit.

[pete]

I'm finally getting close to being able to make some progress again.

Thanks to a very generous mate, I have the use of his spare head to get me on the move. I'll still need to rebuild mine but I can do that later.

I also finally picked up a stator and sprocket cover and have also finally finished the repair on the ignition cover.

I have a cunning plan for the sprocket cover which I'll endeavour to tackle next, then I can hone the cylinders and get those and the three covers ready for paint.

The various head nuts and piston wrist pin circlips are all on their way from the US but they've been in transit since the 6th July, so not sure when or if they'll ever get here at the moment. They made it to Australia but I suspect the new GST import law is going to throw a rather large spanner in the works there.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

[steve murdoch]

Shipping delays are extra annoying.
I can always find reasons on my own to procrastinate, i don't need any outside help.

[nvr2old]

The engine covers alone will keep you busy for an afternoon or so.. Always nice to see progress on this bike, Pete.