1984 Katana 7/11

[pete]

Yep Sam, although the waiting ended up being for the best... started looking at putting more stuff together on Sunday and realised I was missing more bits so I had to order more stuff... then thought I need to replace the footrest and rear master cylinder bolts where the generic black ones I put on had already started to rust (yep, rust, not moved an inch and rusting, not happy!)... so I ordered those as well... I think our much preferred dealer over here is really happy with me at the moment somehow... (they're not a stealer either, they're a real fair dinkum dealer)

Anyway, everything not in stock arrived yesterday and all got posted so I should have a bunch of stuff I can get started on tonight. Yay!

[Sam 78 GS750]

True, some of my best progress has come from waiting for parts... I usually tackle something tedious I've been avoiding, thinking I'll just get started on it until my parts come. usually it's done by the time my package arrives. I'm just about done sorting out my wiring because I've been waiting for parts...

That sucks about the bolts rusting already... I've actually been rubbing some wizards power seal on some bolt heads... not new ones, but the ones I've either replated or just polished...

[pete]

Yep I know what you mean, I definitely have stuff I've procrastinated on but I also know there's fast approaching a time where I'll be either waiting or out of $$ so those bits can get done.

Haven't heard of wizards power seal but I might have to look into it... it's annoying for sure! I think in future for non-genuine bolts I'll stick with zinc plated rather than black, as the zinc plated ones seem to be fine.

All my outstanding bits arrived from the dealer yesterday, so I grabbed my gaskets and set to it.

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Sump cover is on at last.

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All the retainers under the clutch are in as well as the oil pump and mechanical advance.

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The starter clutch/rotor is on and all torqued up as well as the shifting shaft oil seal and neutral switch, although I still need to sort out the wire for the neutral switch and get it protected and terminated yet.

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I've yet to get the oil pressure switch and starter motor in but I have all the bits to do so now.

Aside from the clutch and case covers that pretty much wraps up the bottom end, but I'm not sure if I'll put the clutch in just yet or leave it until the head and barrels are on and it's all in the frame to save a bit of weight during the install. I don't think it will make much difference though.

Next up I can look at getting the cylinders honed and check the valves and seats out to see if they need any attention.

I also have some proper bolts to replace the annoyingly rusted footpeg and rear master cylinder bolts as well.

[nvr2old]

Fun to watch it coming together, Pete.

[pete]

Cheers Larry, fun putting it together too I wish the pace was a bit quicker but I must be patient, good things take time right?

I got the oil pressure switch and starter motor in last night, no pic's though as it's a bit tricky with the bottom end still inverted.

However those ugly rusted footpeg and rear master cylinder bolts have been replaced and are much prettier.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

Now on to the top end...

[pete]

I've been a bit under the weather so no real progress but I did get some top end inspection done on Sunday and I reckon things are looking good.

All cam caps and bolts are accounted for so I just need to get head nuts. I'll have to get them in from the US though as four of those are listed at $103.40 each from my preferred local dealer here but only $US6.40 from Partzilla... big difference!

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I had a close look at the valves and seats, and they look in much better shape than the ones on the 450 did when I rebuilt it, so I'm happy enough to just finish cleaning the bottom of the valves up with a wire wheel and then lap them in.

To me the valves don't need facing and the seats don't need cutting.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

The pistons look all good too, again just need a bit more cleaning up.

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The valve spring free lengths all measure good but I've yet to measure them with weight on to check tension.

The guy who did the crankshaft truing did say he may be able to rustle up a lightly used set of racing springs which will help reduce valve seat wear, so I'll check that when I contact him about the top end gaskets next pay and see if that's an option or not. Depending on price that could be a nice little upgrade.

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The valves feel like they all sit in nicely and appeared to have a nice bit of suction removing them with my finger placed over the valve stem seal, so I've just picked a spot for them all and located them in an egg container ready for cleaning up and lapping in.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

[pete]

I'm beginning to think the only reason this top end was pulled apart was to do the porting job, and a porting job has definitely been done. I've not looked at another GSX1100 or Kat head before to see how they look stock, but it's obvious to me it's been done. No idea if it's a good job or not of course.

Not so easy to photograph for me either...

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Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

The only other catch I've discovered is the ignition cover, and either I've got the wrong mechanical advance unit on or the cover's not quite right... I'm leaning towards the wrong cover though as the advance bolts on with the correct bolt, and the fiche calls for 30mm long screws which look like they'd be the correct length also.

Basically the cover seems too shallow, hitting the advance before sitting on the gasket surface. Can anyone confirm for me and maybe have a pic of how it should be?

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

I think next up is honing the cylinders and lapping the valves in ready for a leak down test.

Then the cylinders and head need painting ready to assemble, so I'll need to get rings, top end gaskets and valve stem seals, and some paint real soon.

[Greg B]

That really looks like an 1150 cover.
Much to shallow to be an 1100 cover.
And the 1100 covers have a shallow recess for the emblem. The 1150 covers have the raised boss visible in your photo.

[Greg B]

1100 cover.
(One of these days I'll figure out how to orient photos)

[Greg B]

1150 cover.
Disregard the hole where the dyna ignition pokes through.

[Nessism]

HD valve springs usually increase loads on the cams, rockers, and seats. Better do some research before making a purchase.

[pete]

Cheers Greg, sorry I forgot to update that yes, spot on it's been identified as the later EFE cover. A mate has an earlier cover for me that needs a bit of road rash tidying up so that works for me. I'll need to paint whatever cover I get anyway to match in with the VHT.

Yep Ed, makes sense! I was wondering about that sort of thing... the guy's pretty cluey and knows his GSX motors and his thoughts are that if you're springs are even a bit worn it lets the valves not seat quite 100% properly when closing, which increases wear of the seat. That does make some sense to me, but there's always a trade off right? I'll definitely need to make more inquiries when I give him a call and find brand, type etc. to look into it a bit more.

[pete]

Yesterday I decided to take care of the chain guard and finally make the new headlight relay mount.

I had to weld a little tear in the chain guard first as well as give it a little tweak here and there to get it pretty much straight.

My welding seems to have improved too... this was after wire brushing but before grinding.

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Then I got some primer on.

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Untitled by starpoint73, on Flickr

Then some satin black.

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Untitled by starpoint73, on Flickr

[nvr2old]

Piece at a time, Pete, piece at a time, eh..?

[pete]

Yep Larry that's it! Be nice to have a bit quicker progress but if I do too much too soon I'll just hit the end of the funds and be twiddling my thumbs for a while, steady does it right?

The front cowling wings turned up from back order the other week and the screen mounting rubbers were in with them, so I mounted them all up, nice to have the front cowl complete finally.

I had to mount it to make sure the new headlight relay mount clears the cowl now, which it does with plenty of room.

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There's also plenty of room to get to the headlight adjustment knob now as well, and the forks still have plenty of clearance also.

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The chainguard looks reasonably neat now too.

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