750 Katana Resurrection

[salty_monk]

There's a good crowd in the UK that do Stainless replacement pistons...

[KiwiAlfa156]

More bent bits to straighten



One of the headlight ring mounting tabs was missing so cut one out of panel steel and sweat soldered it in.



Rear caliper pistons are pitted, so will have to be replaced

[psyguy]

West Auckland, my friend.

I'm out west, too

What are your gremlins doing?

Two cylinders not firing.

https://www.thegsresources.com/_forum/showthread.php?262189-No-signal-from-(new)-Dyna-S-Is-my-ignitor-box-dead

But I think I got that sorted, fired it up just this morning and seems ok now. But the headlight no longer works

[KiwiAlfa156]

West Auckland, my friend. What are your gremlins doing?

[psyguy]

Thanks! Look out for it on the streets when she's finished

What region are you in?
I'm chasing some electrical gremlins atm but hope to be on the road soon

[salty_monk]

Looking good! Probably straighter now than when it left the factory...

[KiwiAlfa156]

Thanks Fellas.

Doing bits and bobs

[Kiwi Canuck]

Thanks for posting on GSR, brings back some memories for me, several of the bikes I've restored have had similar issues, many broken and stripped bolts/screws, bent rear sub frame, all the usual fun stuff.

Even though it's frustrating at the time, it brings so much enjoyment when you are able to fix all the issues and get the bike back to how it should be.

Carry on, looking forward to your next installment.

David.

[KiwiAlfa156]

Great work, mate, keep it up!

Thanks! Look out for it on the streets when she's finished

[psyguy]

Great work, mate, keep it up!

[KiwiAlfa156]

I think I know how this Kat got bent....



I'm sure the POs brakes didn't squeal, but his butt certainly would have when he grabbed a handful of drip lubricated brakes and bugger all happened.

And yes the brake pins had been tightened to about 500 ft-lb requiring a piece of pipe on a breaker bar to loosen. How the anti-squeal shim got stuck in the top of the caliper is anyone's guess.



On the bright side the pistons and seals are in excellent condition. The fork oil had rotted the sliding pin dust boots, but the piston dust boots were intact.

[Big Block]

Looks great, fun to watch this one.

[GS1150Pilot]

This thread is inspirational. I really need to get back to restoring my '82 CB900f.

[KiwiAlfa156]

Frame finished in silver. Tyres ordered. Next step, rolling chassis assembly.

[KiwiAlfa156]

Final confirmation of alignment. Checked the rake measured at just under 28° while sitting on the rims. So very close to the 28.5° GSX750S spec.



Some of the factory welding on the frame was really bad. Either the frame welder had a hang-over or they were a beginner. Holes aplenty. The arc welder was handy, and setting up the MIG seemed an unnecessary hassle. Not perfect, but better than what was there.




Loose paint and surface rust removed prior to rust treatment and etch priming.