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1981 GSX1100 Katana Based Project
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Originally posted by steve murdoch View PostThis is a great follow!
Thanks for sharing it with us.
Cheers.Last edited by Shin-Ken 1074; 09-27-2023, 10:08 PM.Badgezz, we don need noh stinkin' badgezz!
Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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Here is the top plate before being painted, gives a better idea on how the profile was changed. Filed off all the curves and went with flat surfaces and angled edges.
DW top plate a by Max Mutarn, on Flickr
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Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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Rear master cylinder frame bracket. By trimming the edges of the bracket and drilling it removed 92 grams from the bracket.
This is the bracket before mod.
OEM mount by Max Mutarn, on Flickr
Bracket after mod.
OEM mount mod a by Max Mutarn, on Flickr
Some of the metal removed from the bracket, swarf from drilling and cutting not included.
OEM mount mod b by Max Mutarn, on Flickr
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Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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Originally posted by bull958 View PostMax, the pictures really add something to the rest of us mere mortals. Glad you got it figured out and great job so far, Im in awe. Steve
Cheers.Last edited by Shin-Ken 1074; 09-28-2023, 06:59 PM.Badgezz, we don need noh stinkin' badgezz!
Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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Lower steering stem bearing replacement, not difficult however, I wanted to make sure installing the new lower bearing went without a hitch. Holding a steering stem balanced and centered on an old bearing or piece of pipe with one hand while using a hammer in the other hand hitting the drift to drive the new bearing home is the usual back yard DIY way and has worked since day one but I wanted something that did the job without the chance of it going wrong. If you have access to a workshop or want to pay someone to do the job then all bets are off and this one operator DIY method doesn't apply.
Had some steel round stock, 20mm flat plate and a section of beam in the shed so decided to make a jig for one job - lower bearing installation.
Steering bearing jig 1 by Max Mutarn, on Flickr
steering bearing jig 2 by Max Mutarn, on Flickr
steering bearing jig 3 by Max Mutarn, on Flickr
Last edited by Shin-Ken 1074; 09-28-2023, 07:03 PM.Badgezz, we don need noh stinkin' badgezz!
Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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Like many others I prefer to cool down the steering stem prior to installing a new lower bearing. Heating the bearing as well as cooling the stem is another method however, I have found that just cooling the stem contracts the material a few microns and allows the bearing to be seated on the seal and shim without the need for heating the bearing.
I leave the stem in ice for an hour. Have the lower seal, shim, bearing, drift, hammer and spanner within arms reach of the jig.
Stem out of the ice, dry stem off and apply the same grease around the bearing area of the stem as the lube used in the bearing. Position the lower seal, shim and bearing on the stem, bolt the stem in position on the jig. I used an ally drift made from aluminium round tube and sized to match the bearing inner race, place drift on the bearing and three taps with the hammer and it was seated home on the seal and shim in a few seconds. Very happy with how it went.
lower bearing install 1 by Max Mutarn, on Flickr
lower bearing install 2 by Max Mutarn, on Flickr
lower bearing install 3 by Max Mutarn, on Flickr
lower bearing install 4 by Max Mutarn, on Flickr
Last edited by Shin-Ken 1074; 09-28-2023, 06:44 PM.Badgezz, we don need noh stinkin' badgezz!
Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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Next up is the swing-arm. Where the gusset joins each side there is a section of gusset that is not welded to the the arm, if it isn't welded then it is not needed so those two sections are coming off. The excess weld runs around the gusset can also have a tidy up. To fit the 2005 GSXR1000 K5 rear underslung brake caliper to a stock 1981 Kat swingarm I am going to have a tab welded to the underside of the swinger that will secure the caliper bracket to prevent the caliper from rotating and allow rear wheel movement when the chain is adjusted. Caliper position and chain alignment need to be done to work out the location for the caliper bracket tab. Before that, the K5 caliper mount needs to have a bush made to make it fit the 20mm Kat axle.
DW brake 3 by Max Mutarn, on Flickr
DW brake 2 by Max Mutarn, on Flickr
DW brake 5 by Max Mutarn, on Flickr
DW Chain wheel alignment by Max Mutarn, on Flickr
caliper position 1 by Max Mutarn, on Flickr
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Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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Badgezz, we don need noh stinkin' badgezz!
Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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New swing arm bearings and bushes fitted as well as making an aluminium bearing spacer.
DW ally swing arm bearing spacer by Max Mutarn, on Flickr
Badgezz, we don need noh stinkin' badgezz!
Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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With the caliper location and chain alignment sorted the next step was having the axle spacers made in aluminium. These have been made and I polished them before sending off to be anodised gloss black. With a gloss black finish best results are when the parts are polished and is much cheaper if you do it yourself.
DW axle spacers 1 by Max Mutarn, on Flickr
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Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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While waiting for the axle spacers to be made I made a set of adjuster blocks in ally to replace the OEM steel units. No milling machine at my place so its hacksaw and file time.
DW block 1 by Max Mutarn, on Flickr
DW block 2 by Max Mutarn, on Flickr
DW block 3 by Max Mutarn, on Flickr
DW block 4a by Max Mutarn, on Flickr
DW block 6 by Max Mutarn, on Flickr
DW bolock 1 by Max Mutarn, on Flickr
Badgezz, we don need noh stinkin' badgezz!
Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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OEM SZ steel block/bolt v DW ally block and Titanium bolt.
OEM steel block by Max Mutarn, on Flickr
DW ally block titanium bolt by Max Mutarn, on Flickr
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Shin-Ken 1074
1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
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