1984 Katana 7/11

[pete]

Cheers Larry! I'll have to break out a clean rag and give it a rub down, I'd forgotten you'd mentioned that.

You're right about it being bittersweet, I definitely like having something to wrench on, customise, paint, etc. I suspect having my very own Kat to ride will distract me from that quite a bit though

And also just to ease Greg's mind, I raised the forks in the triple trees a few mm's on the weekend also to fix that up

[pete]

I've made and installed a plug for the oil gallery under the oil filter cover to force the majority of the oil flow through the oil cooler.

I made it so I had to gently drift it in so it wouldn't pop out, and went with a 2.5mm diameter hole to replicate the EFE cover setup. If I need to get it out for any reason a timber screw threaded into the hole and some pliers for leverage should have it sorted.

Untitled by starpoint73, on Flickr

[pete]

The plan was to post a video this morning of the first ride up the driveway under her own power, however we all know what happens to plans!

I borrowed an AFR gauge and got that all set up to see if I could get the pilot circuit sorted and at least get an idea if the needles are in the right place to start with.

I got the motor nice and warm yesterday then took note of the gauge.

The first thing I saw was the carbs are jetted way too rich when the throttle was opened (even 1/8 to 1/4) with readings down to 11 on the gauge.

I still couldn't get it to idle at all. It's either wind the idle screw in so idle is at 2K RPM or let the screw out a bit and the rev's would just drop to nothing and it would stall.

The needles have now been dropped a notch to the middle position, and that has definitely made an improvement when opening the throttle, with numbers in the mid 12's to 13.

I then focused on trying to understand what is happening with the pilot circuit, and I noted that when the motor stalls out, the readings on the gauge jump up to 15 to 16!

I wound the air screws in to 1/4 turn out and still no noticeable difference, so it looks like they're way too lean with the 17.5 pilot jets in there.

A Google around revealed plenty of posts with people running up to size 30 and 35 pilot jets in there, so this doesn't seem unusual, especially when not running a stock airbox setup.

Fortunately I have some 22.5, 25, and 27.5 pilots here from when I was trying to sort the wee beastie's carbs out, although I only have two of each.

I'm going to try 27.5's in carbs 1 and 2 with 25's in 3 and 4. I know the AFR gauge will give me a combo of both but I should be able to see if that at least gets an idle happening and the plug colour should show me if I'm heading in the right direction at least and if so, which size looks better.

The good news is there was no smoke yesterday! One little puff on the initial start and that was it, nothing after that.

In other news I've got the front tyre organised to get fitted tomorrow, and I also called the place where I bought the frame, and they have an engineer who can do the L01 import compliance for $150, which is about half the price of the others who do it. I have to take the Kat down there to get it done is the only catch but I'm sure I can organise that.

[pete]

I got an idle! Wasn't perfect by any stretch but it does idle and appears the opposite and too rich now. Once warmed up the numbers hit low 12's, and opening the throttle a bit hits the 11's. I forgot to add some tape to mark the throttle position to see if I'm getting 1/4 throttle or not but I suspect I'm not, so this is likely all the pilots and air screws. Closing the throttle leaves the RPM's up for a while and she doesn't want to drop back down, also telling me it's rich.

This is with the 27.5's ending up with the air screw 2 turns out and the 25's with the air screws one turn out, so I need to try swapping out the 27.5's with the 22.5's. My gut tells me that will get me slightly rich which means I just need to order another pair of 22.5's and I should be all sorted.

It was quite awesome just to be able to ride it up the driveway

The new front tyre was done yesterday also, so I have a fresh BT45 on the front.

I have video evidence of the driveway ride (with my housemate starring in it) which I'm getting sorted to upload, will post again when it's ready.

Now to hurry up and wait for the next two pays so I can get her on the road! Oh, and get some hand grips too!

[pete]

Here 'tis! You can hear the high idle while it's out of camera view and I have to wind out the idle screw a little. Excuse my house mate...

[steve murdoch]

Congrats on the baby steps, Pete.
Sounds like a Honda DOHC clutch rattle caused by out of synch carbs.

[Charlie G]

Wahoo! That is a big deal!

[Skinner]

Congrats Pete! That exhaust sounds fantastic BTW.

[Carter Turk]

Closing the throttle leaves the RPM's up for a while and she doesn't want to drop back down, also telling me it's rich.

I always thought a hanging idle means it's lean or a vacuum leak is present?

[pete]

Congrats on the baby steps, Pete.
Sounds like a Honda DOHC clutch rattle caused by out of synch carbs.

Cheers Steve! Unfortunately I know what the rattle is and it's something I should've fixed earlier although it's not the end of the world. One of the springs on the clutch basket is broken and I had completely forgotten about it until I heard that rattle... at least it's something I can come back to or perhaps get another basket to swap out later.

Wahoo! That is a big deal!

Yes indeed Charlie! Exciting times alright!

Congrats Pete! That exhaust sounds fantastic BTW.

Cheers Skinner and yep 100% agree, really happy with the sound! I was told the muffler would be quiet, but I think it's a great note and volume, not too quiet at all.

I always thought a hanging idle means it's lean or a vacuum leak is present?

You know I thought the same, but on the 450 I've had a way too rich pilot setup on the 450 do the same, it's a different behaviour to a hanging idle though. This behaviour is more like you haven't let it warmed up enough and have set the idle screw too far in, so the idle is too high, if that makes any sense at all.

The AFR gauge definitely confirms too rich though, numbers in the high 11's and low 12's is definitely too rich!

I've swapped the 27.5's out for some 22.5's last night so I'll see how it goes this morning so I can hopefully order whichever pair I need in the right size so I can get all four carbs the same.

[pete]

I've ordered a pair of 22.5 pilots, was still running a bit rich with the 22.5's and 25's so that should be the way to go.

I now have an oil leak to sort out which is actually coming from the oil seal for the drive shaft in the gearbox.

When I put that seal in with the rebuild, I noticed it was twice as thick as what came out and I couldn't use the retainer, but I figured it was just a newer updated version and didn't think anything of the fact that it protrudes out of the case.

However, it's an issue as it interferes with the chain which has chewed it out.

There's no way for the seal to sit further in as it's too wide, so I'm very confused here.

Anyone encountered this at all? I'll have to give the dealer a call this week and see if they're aware of anything.

I've double checked I ordered the right part number (09241-47004) and found it on the invoice to verify, and when I get my orders I always go through and check the part numbers match what I ordered, so I'm positive they sent me the right thing. Of course I tossed the original out so I don't have it to compare now, but I do have the retainer.

The big question is can I replace it without splitting the cases!?

Untitled by starpoint73, on Flickr

[Greg B]

There is always the possibility the wrong seal ended up in the right wrapper.

[pete]

True Greg, although I've not encountered that myself just yet, could be a first time though?

So far I've not encountered anyone else with this issue, but I wouldn't be surprised if Suzuki superseded the part in recent times and I'm the first to find this issue due to the 530 chain/sprocket setup.

I didn't get time to call the dealer yesterday but hopefully today I can talk to them.

[pete]

I spoke with the dealer yesterday, and that part has never changed, and he confirmed the one he had in stock matches what it should be which I then ordered.

Last night I removed the incorrect one... which turned out to actually be two of the correct ones stuck together, and they were really quite stuck together! The chain hitting them didn't separate them, but using self tapping screws to remove them did separate them. Of course I had to ruin both plugs to remove them.

Can't help feeling like a complete idiot, and the thought of two stuck together never even crossed my mind when I initially received the order. They certainly didn't just fall apart either.

Anyway, the new one should arrive today, so I'll pop it in the freezer as soon as I get home this arvo so hopefully the metal part will shrink itself down enough to help get it installed. I'll use some threebond as well just to be 100% sure it all seals up oil tight. I'll use one of the damaged plugs with a socket to gently drift it home and get the retainer back on.

You live and learn right?

[nvr2old]

I'm chuckling as I post this, Pete..that's a funny story we can all relate to..