skellys kat rebuild

by **skelly** » Mon Apr 17, 2017 7:46 am

Morning all.
I have been busy building my katana.
more to follow.
Skel.

by **skelly** » Mon Apr 17, 2017 5:15 pm

: kat1.jpg (87.86 KiB) Viewed 18719 times

Essentially its a GSX1000SZ, it was never standard when I got it and I don't intend to sell it so sorry to the purists but it should make a worthy project.

So, this is where its at so far.

1989 EXUP front end, wheel, brakes, mudguard, forks, yokes, the lot.

1989 EXUP rear end, swingarm, wheel, monoshock linkage with adjustable dogbones and underslung brembo caliper.

1986 VF400 rearsets.

1100 EFE head, 1170 Wiseco kit, straight cut primaries, welded crank, EFE gearbox,

GPZ1100 throttle bodies,

GSX1400 injectors.

Lots of other bits that I will go through at some point but thats the bare bones of it.

The photo is how it looked when I stripped it down in 2007.

Cheers.

Skel.

by **skelly** » Mon Apr 17, 2017 5:19 pm

: kat2.jpg (75.61 KiB) Viewed 18719 times

Righty.

While the cases are away being blasted & painted at Faircharm restorations in Leicester, I've pressed on with getting the frame to a point where I can send it off for blasting & powder coating.

Its coming along ok after some head scratching and measuring.

The main bits to do were some new rearset brackets, if you look on the photo above, you can see the two kinda neanderthal ones that I put on years ago.

Was never real happy with them so I decided to make new ones out of some tube and some turned, c/bored and threaded bosses.

Spent quite a while getting the height, angle and spacing sorted out, they were never completly nob on but they are pretty good now.

by **skelly** » Mon Apr 17, 2017 5:23 pm

looks better with the new mounts.

by **FBJ admin** » Mon Apr 17, 2017 8:32 pm

Hello bud. Pics are great and speak a thousand words

by **skelly** » Mon Apr 17, 2017 8:46 pm

They are nob on now, the only slight issue is the width, the VFR r/h hanger has the master cyl on the inside, its a very small one so I had to get it to just miss the swingarm,

I also had to space the l/h one out so that the gap between the swingarm was equal on both sides where the pillion pegs go.

Been modding the headstock spindle today.

The std EXUP one is too long by about 15mm so I very carefully pinched the end in the chuck and supported the other end in a live center, clocked it, then machined the correct diameters into it so that the top brg would fit on the correct part of it and then the bits for the threads ect.

by **skelly** » Mon Apr 17, 2017 8:49 pm

Got to the point where I'm ready to extend the threads on the steering stem but there was a slight problem.

I am missing a 44 tooth changewheel for my lathe which means I will struggle to screwcut a metric thread, also I cant get the same ratio with any other changewheels that I have.

so, looked on the bay and Cromwell to find 22x1 and 25x1 dies,, how much ????

Ended up ordering two from China for about a fiver each, in the meantime I will be chasing a changewheel for a Harrison M300.

Spent last night making a coffee table out of a large cable reel then managed a hour in the workshop just dressing the frame in places and working out some sort of bracket for the dyna coils that arrived in the post.

Then thought I would mill some holes in the sproket cover..

by **skelly** » Mon Apr 17, 2017 8:52 pm

Finished making the battery box.

I wanted it to follow the lines of the frame, none of this big gap in the middle here.

Also wanted room for a piggyback reservoir on the rear shock rather than a remote one that it currently has.

The original electric back plate will stay also, I reckon there are some things that make it katanaish & thats one of them.

The High pressure fuel pump and filter will sit on a horizontal plate in front of the battery box, behind the air filter.

by **skelly** » Mon Apr 17, 2017 8:54 pm

Was pondering how to mount the Dyna coils as the original mounts were no good.

Settled on two bits of 20mm box with m6 threaded bosses welded in.

Seems to work.

by **skelly** » Mon Apr 17, 2017 8:55 pm

Got the Kat frame back from the powder coaters