1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

I wasn't happy with the carbon screen I made and how heavy it turned out to be. The first couple of screens I made were O.K. but went in the reject pile for various reasons. The weight of the carbon screen for the DW 180 has been bugging me for the last week so I had to do something about it. I have picked out the best of the reject screens I made and will use it for the DW 180. At 99 grams it is 1/3 lighter without the trim fitted and will polish up O.K. for use.

Carbon screen MKII b by Max Mutarn, on Flickr



Carbon screen MKII c by Max Mutarn, on Flickr

[Shin-Ken 1074]

The best of the reject screens is now the MK II screen for the project. Polished and ready to go and at 99 grams I am happy with it.

Carbon screen polish by Max Mutarn, on Flickr


Carbon screen MKII by Max Mutarn, on Flickr

[Shin-Ken 1074]

Now with new oil and seals the forks are ready to go on. TNK refurbished clocks with the top plate before fitting the forks. TNK clocks are the same weight as OEM clocks because they are OEM clocks with a TNK dial, just with a different look using the white dial.

TNK clocks by Max Mutarn, on Flickr

[GSX1100 dreamn]

Got carbon fibre ??

https://handl-mag.com/goodlooking/%e3%82%af%e3%82%a9%e3%83%bc%e3%82%bf%e3%83%bcgsx1100s-%e3%82%b9%e3%82%ba%e3%82%adgsx1100s/

186kg

[Jero+]

What an epic build!
Blows my mind the amount of weight you already saved!
Compliments!!!

[steve murdoch]

I really like the look of the white background on the gauges.

[Shin-Ken 1074]

Got carbon fibre ??

https://handl-mag.com/goodlooking/%e3%82%af%e3%82%a9%e3%83%bc%e3%82%bf%e3%83%bcgsx1100s-%e3%82%b9%e3%82%ba%e3%82%adgsx1100s/

186kg

Yeah, a very trick custom Kat, 186 kg eh?

[Shin-Ken 1074]

What an epic build!
Blows my mind the amount of weight you already saved!
Compliments!!!

Thank you Jero+, got a bit more done today.

Cheers.

[Shin-Ken 1074]

I really like the look of the white background on the gauges.

Hi Steve, Yes, the white dial gives it a fresh look, I like it a lot!

Cheers.

[Shin-Ken 1074]

Front wheel, clocks and forks today. Revised front wheel weight, complete wheel assembly is now 12,950 grams.

DW complete F wheel by Max Mutarn, on Flickr


Clock fork wheel 1 by Max Mutarn, on Flickr


Clocks by Max Mutarn, on Flickr


Clocks and ignition = 1055 g.

Forks = 8,680 g.

Brace = 378 g.

Front wheel weight = 12,950.


Running tally = 147,452 grams.

[Shin-Ken 1074]

I don't think the oil filter cover needs to have more fins than a shark party. Shaved a few grams from the cover and now looks a bit sporty compared to the OEM design.

OEM cover = 227 grams.
OEM cover by Max Mutarn, on Flickr


Shaved oil cover
Shaved cover by Max Mutarn, on Flickr


Oil cover, Ti nuts, filter, O-ring gasket filter spring.
DW 180 cover by Max Mutarn, on Flickr

[Shin-Ken 1074]

Lightened the engine by a few grams today. When the engine was weighed it was fitted with the stock five OEM steel oil gallery bolts that weigh 29 grams each. There are 3 other oil bolts, two in the front of the block for the oil cooler lines and the sump plug. The oil cooler bolts are an issue for another day however, the sump plug has been replaced with one of the hollow ally bolts as well. The sump has not been installed yet so that bolt is not included in the running tally today.

In total the five hollow aluminium bolts weigh 1 gram more than just one of the OEM steel bolts!


OEM oil bolt 2 by Max Mutarn, on Flickr

OEM oil bolt by Max Mutarn, on Flickr


Replacing the steel bolts with hollow aluminium that weigh 6 grams each.
DW oil bolt by Max Mutarn, on Flickr

DW oil bolt 2 by Max Mutarn, on Flickr

5 x OEM oil bolts = 145 grams.

5 x hollow ally oil bolts = 30 grams.

147,452 g - 115 g = 147,337 g.

Running tally = 147,337 g.

[Shin-Ken 1074]

Stator and cover installed today, total weight including Ti bolts = 1,733 g.


EF Stator by Max Mutarn, on Flickr


Running tally = 149,070 grams.

[Rob S.]

You'll have to chain this bike down at night. Else it'll just float away.

[Shin-Ken 1074]

You'll have to chain this bike down at night. Else it'll just float away.

Would have to use an aluminium chain to keep in step with the build.