1984 Katana 7/11

[pete]

I didn't end up with as much time as I normally get on a Sunday, so not as much progress as I'd hoped.

I did at least get the loaned head somewhat degreased, cleaned up the gasket surfaces, and wire wheeled the carbon build up from the valves.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

I at least got all four sets of rings on the pistons and got the pistons installed.

Untitled by starpoint73, on Flickr

I'll be out tomorrow but hopefully Tuesday morning I'll be able to get the cylinders on.

Got a few other things on the go for my week off so if I can at least get the head on before I go back to work next week I'll be happy. I'd really like to get the motor in the frame but that could be a bit ambitious.

[Sam 78 GS750]

That's some good progress, Pete. I may have missed something, but why a loaner head? Are you saying you're going to assemble and then give the head back to someone at some point?

[pete]

Cheers Sam, yeah you must've missed my inspection of the valves etc.

Basically my head is screwed and needs rebuilding. There are a couple of options available, but basically if I do the head now the Kat's not going to be done any time soon. The best option is to get the guy who did my crank straightening to rebuild it which will end up with new valves, guides, springs, and the head decked if it needs it etc. That, however, will set me back ~$AU1200 depending how much work it is.

One of my mates came to the rescue and has loaned me his spare head which he's not planning on using any time soon. When he took it off it was working well, no smoking etc. so I'm just cleaning it up and using it to get on the road while I build up $$ to get my head sorted.

I have good mates

[pete]

I got some unexpected time and a win yesterday.

Put some loaned you-beaut DIY piston ring compressors to good use.

Untitled by starpoint73, on Flickr

Got the 30 something year old O rings removed from around the base of the cylinders after realising I hadn't done that yet, and they were like plastic.

New O rings and base gasket installed and cylinders are on.

Untitled by starpoint73, on Flickr

Then a new head gasket went on along with the loaner head and all head nuts torqued up to spec.

Untitled by starpoint73, on Flickr

Camshafts still to go in, then it'll be time to get the motor in the frame.

[Nessism]

Ha! "Loaner" head that will never go back! Buy that friend of yours lots of beer!

[Charlie G]

Pretty cool Pete!

[gs scott]

Wow Pete - nice progress!!

[pete]

Cheers guys! Yep Ed, I owe him alright! Definitely still need to rebuild my own head though... I actually owe him a fibreglass single seat setup similar to mine which I hope to do soon, least I can do to pay back his generosity. I still have all the materials from doing mine so it's just time and effort.

I did hit a bit of a set back tonight though and something just ain't right getting the camshafts in.

Lined up the timing marks to do the cam timing, got the exhaust cam in, and immediately I could see that the inlet cam isn't going to have enough chain to sit in the journals, and I was right.

Untitled by starpoint73, on Flickr

I can't see that the chain is bunched up in the bottom and it certainly feels like it rotates properly when I turn the crank.

I'm wondering if there's something screwy with the rear cam chain guide?

Hard to get any pic's down the tunnel but I tried..

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

I went back through my Mick Hone orders and the cam chain I ordered was the right one (120 links - 12760-45040), and I always check off the part numbers ordered against what I received, so I know I ordered and received the right part number.

Is there something I'm missing here? Can I have the rear cam chain guide out of whack somehow so it's tensioning the chain or something like that?

At this point in time I see no choice but to rip the head off again.

[Nessism]

Sometimes the cam chain bunches up around the crank in a way you can't see when looking down the tunnel. Salty_Monk (Dan) and I had this issue recently when assembling his 1100G engine. You might want to try holding up the cam chain while turning over the engine a few times with a wrench to make sure the chain is free on the bottom.

[pete]

Cheers Ed, will give that a shot. I'm thinking surely it has to be something simple? I'm also thinking having the front chain guide in may be preventing unbunching as well so I'll see if I can get that out to help.

[pete]

Crisis averted!

Untitled by starpoint73, on Flickr

Pulled both cam shafts out, and after removing the front cam chain guide and rotating the crank all of a sudden I got extra cam chain length... must've been bunched up after all. I guess at some point I hadn't held it quite tight enough before putting the front guide in.

I got the cam chain tensioner rebuilt today as well.

Checked the timing 4 times before torquing down the cam shafts and installing the tensioner, but somehow I've still screwed up... discovered tonight while cranking that number 4 is rising as the exhaust cam is opening and stopping it rotating.

I don't have the motivation to loosen the cams and remove the tensioner tonight to sort it but I'll go back to square one in the next couple of days and get it sorted, will be another obvious thing I've missed guaranteed!

[pete]

Turns out I'm either blind, stupid, or possibly both... I was timing using the T mark for cylinders 2/3 rather than 1/4... so that's all sorted now.

Got the frame protected ready to get the motor installed on Sunday.

Untitled by starpoint73, on Flickr

And got my first brake component assembled.

Untitled by starpoint73, on Flickr

Looking forward to Sunday!

[nvr2old]

Step by step, inch by inch...

[zuluwiz]

Cheers, Pete! You are an inspiration to the rest of us. Am still watching your build with great interest. Can't wait to hear you've got it on the road.

[gs scott]

Pete - Nice work!! I better get moving or you'll be done!