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1984 Katana 7/11

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    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.
    1982 GS450E - The Wee Beastie
    1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

    sigpic

    450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

    Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

    Comment


      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?
      sigpic

      Check out my rebuild thread here: https://www.thegsresources.com/_foru...GS-750-Rebuild

      Comment


        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
        1982 GS450E - The Wee Beastie
        1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

        sigpic

        450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

        Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

        Comment


          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.
          Last edited by pete; 11-20-2018, 06:13 PM.
          1982 GS450E - The Wee Beastie
          1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

          sigpic

          450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

          Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

          Comment


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

            To measure is to know.

            Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

            Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

            Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

            KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

            Comment


              Pretty cool Pete!
              sigpic
              83 GS1100g
              2006 Triumph Sprint ST 1050

              Ohhhh!........Torque sweet Temptress.........always whispering.... a murmuring Siren

              Comment


                Wow Pete - nice progress!!
                Scott
                1982 GS1000S #1 bought in 84, #2 gone, #3 in hibernation
                1983 GS1100ES #1 (bought in 03, July 09 BOM, 65k traded in 17), #2 New daily rider, #3 in hibernation
                1982 GS1100E Red #1 - Original owner, sold in 93, #2 (Red) sold in 20 to Andy B
                2018 Gold Wing Tour - new out of the crate :) 1st non-Suzuki in 38 years
                sigpic

                Comment


                  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.
                  1982 GS450E - The Wee Beastie
                  1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                  sigpic

                  450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                  Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                  Comment


                    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.
                    Ed

                    To measure is to know.

                    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                    KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                    Comment


                      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.
                      1982 GS450E - The Wee Beastie
                      1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                      sigpic

                      450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                      Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                      Comment


                        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!
                        1982 GS450E - The Wee Beastie
                        1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                        sigpic

                        450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                        Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                        Comment


                          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!
                          1982 GS450E - The Wee Beastie
                          1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                          sigpic

                          450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                          Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                          Comment


                            Step by step, inch by inch...
                            1979 GS1000S,

                            1982 Honda CX500 Turbo, 1982 Honda MB5 w/CR80 motor, 1977 Honda "nekid" Goldwing, 1976 Honda CB550F cafe', 1972 Honda XL250 cafe'

                            Comment


                              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.
                              Expecting the Spanish Inquisition
                              1981 GS850G: the Ratzuki
                              1981 GS1100E

                              Comment


                                Pete - Nice work!! I better get moving or you'll be done!
                                Scott
                                1982 GS1000S #1 bought in 84, #2 gone, #3 in hibernation
                                1983 GS1100ES #1 (bought in 03, July 09 BOM, 65k traded in 17), #2 New daily rider, #3 in hibernation
                                1982 GS1100E Red #1 - Original owner, sold in 93, #2 (Red) sold in 20 to Andy B
                                2018 Gold Wing Tour - new out of the crate :) 1st non-Suzuki in 38 years
                                sigpic

                                Comment

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