My Kat rebuild

[GSX1100 dreamn]

Soooo...
Bandit suspension from donor bike onto Kat conversion, so far so good.
Have been tossing up about the speedo drive.
Mechanical drive front axle as per Kat,
Front sprocket pickup electronic as per Bandit.
Decided to try the Bandit setup below.


Then a dummy run on the spare 750 motor,


And that was it,
Pulled my 1100 apart to drill and tap its front sprocket shaft and nope, nothing, using the same drill bits blunt straight up. New drill bit (cause I,m a crap drill sharpener) and blunt too. The 750 drilled and tapped like a hot knife in butter.
So I am wondering are the 1100 shafts hardened compared to the 750 ???
Cue scratching head and a glass of wine(s).
Cheers Andrew.

[GSX1100 dreamn]

Happy with the rear wheel alignment.


Chain run next.
Cheers Andrew.

[GSX1100 dreamn]

Made some progress with the speedo trigger. This setup allows me to run the Bandit style of dash.

Used a ball bearing (seen below) to help center the trigger.


Cheers Andrew.

[GSX1100 dreamn]

These are my 3 choices.
I have this one (below) from the donor bike, be it from the faired version.

And these other 2.


Cheers Andrew.

[GSX1100 dreamn]

And maybe this one.

[GSX1100 dreamn]

A bit more progress
Mounted the trigger.


And yet to mount the pickup

A bit of an illusion plenty of clearance to the pump tank

Lets see what shakes loose.
Cheers Andrew.

[GSX1100 dreamn]

Bracket and pickup mounted
If it stays in place I'll connect the bandit dash to see if it works
Bracket and pickup



With the tank spaced out to clear the pickup


And all back together to take me to work tonight

Cheers Andrew.

[posplayr]

This may center the rear wheel on the frame centerline, but it does not align the rear wheel with the same plane. Normally you align the front wheel with the rear wheel (using swing arm fork adjustment opposite chain)after centering the rear.

https://www.thegsresources.com/_forum/showthread.php?149997-Different-methods-of-wheel-alignment&highlight=wheel+alignment

Happy with the rear wheel alignment.


Chain run next.
Cheers Andrew.

[GSX1100 dreamn]

A good point from another forum member was with the SFV650 Gladius dash is that it comes from a 2cyl bike a conceivably the tacho output from my 4cyl ECU my not be compatable with the 2cyl dash tacho.
So playing it safe I am back to 3 choices for now. And I did a mock up of sorts.



Cheers Andrew.

[GSX1100 dreamn]

Well that answers that question the electronic speedo works.

https://youtu.be/5Uq0xReoEuQ

Just need to mount the dash for now.
Cheers Andrew

[GSX1100 dreamn]

Bandit dash mounted atleast for testing purposes for now.
I did silicone the upper housing to keep the water out




Cheers Andrew.

[GSX1100 dreamn]

So I have been running the EFI for a little while now and it has always had a FI fault.


As I was running the Kat dash I never knew until I connected the healtech interogator.


Had a cooling fan fault mainly because I wasn't running the cooling and I also hard wired the cooling fan relay for some accessories fair enough.


Now that I am running the Bandit dash 2 things happen.


1 the fuel gauge flashes constantly as there is no tank sender connected.


2 The FI light stays on and the odometer flashes with CHECK as well.


So to fix it I wired in the original cooling fan relay to the ECU to think it was there and added another relay to power the accessories.



Okay FI light out and I can now access the trip meter for kilometers traveled per tank.


Next I found the resistance values for the tank fuel level sender

Now I just had to replicate any of the values to get the dash to show a fuel level and stop flashing.


A relay I had with 27ohm resistance on the coil side was good enough to do the job.


Now I always have a full tank of fuel cool.


Cheers Andrew.

[GSX1100 dreamn]

I thought Kats didn't like water.

Two days riding in the rain and the dash/bike still works.

Cheers Andrew.

[GSX1100 dreamn]

Got the rear sprocket hub machined 3mm


centered the front sprocket 4.5mm + 5mm spacers

sprockets and chain seem to run centered


and nice equal gaps to frame and tyre


Need to order an offset front sprocket.
Cheers Andrew.

[GSX1100 dreamn]

With the fork extensions added and adjusted for Kat length 810ish




Cheers Andrew.