1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

Starter motor is now in place, starter and bolts = 1,522 grams.

Running tally = 150,592 grams.

[Shin-Ken 1074]

The starter motor cover is one of the parts I made in carbon, the first two were total fails as you can see with this sad example.

Starter cover 1 by Max Mutarn, on Flickr


Got it on the third try.
Carbon cover by Max Mutarn, on Flickr

[Shin-Ken 1074]

OEM steel starter cover.


SZ OEM starter cover by Max Mutarn, on Flickr


Carbon cover and bolts.

Carbon cover and bolts by Max Mutarn, on Flickr


DW Carbon Cover by Max Mutarn, on Flickr





Running tally = 150,617 grams.

[Shin-Ken 1074]

Replacing steel parts with aluminium parts has helped to reduce weight for the DW 180 however, there are times when steel is lighter than aluminium. What form of skullduggery is this! The OEM clip-ons are solid aluminium and with the bar weights come in at 1,474 g. I found a used set of hollow steel clip-ons with aluminium bar weights that are 1,153 g. And the steel bars are also adjustable so the angle can go from a flat bar position down to the point where they will crush your fingers against the tank on full lock.

OEM bars.

OEM bars by Max Mutarn, on Flickr


DW 180 bars

DW bars by Max Mutarn, on Flickr

[Shin-Ken 1074]

I bought these bars because they are lighter than the stock bars however, I really like the additional feature of adjustment, from flat bars to full on drop bars.


DW bars 2 by Max Mutarn, on Flickr


Dw bars 1 by Max Mutarn, on Flickr


Running tally = 151,770 grams.

[Shin-Ken 1074]

Carbon chain guard now installed.


DW carbon guard by Max Mutarn, on Flickr


DW carbon chain guard by Max Mutarn, on Flickr


Running tally = 151,918 grams.

[Shin-Ken 1074]

Shaved oil filter cover, Ti nuts and washer and filter. No oil in engine at this stage as the DW will be going on the scales dry.



DW oil cover by Max Mutarn, on Flickr


Running tally = 152,193 grams.

[Shin-Ken 1074]

Cleaned up the clutch before fitting the newly painted cover.

DW clutch 1 by Max Mutarn, on Flickr


Clutch cover ready to go.


DW clutch cover and bolts by Max Mutarn, on Flickr

DW clutch cover installed by Max Mutarn, on Flickr



Running tally = 153,179 grams.

[Shin-Ken 1074]

Saved a few grams swapping the OEM rubber grips for foam grips that are less than half the weight of the OEM grips.

OEM grips by Max Mutarn, on Flickr


Foam grips by Max Mutarn, on Flickr

[Lorenzo]

And they absorb some high pitched vibrations too

[Rob S.]

I always liked foam. Are they GrabOns?

[Rijko]

Cleaned up the clutch before fitting the newly painted cover.

Clutch cover ready to go.

Running tally = 153,179 grams.

did you remove weight from the clutch cover ?

Seeing how far you go to save weight, did you consider a billet clutch cover, or one with a window ?
Expensive stuff.

[LarsKroghStea]

OEM steel starter cover.


SZ OEM starter cover by Max Mutarn, on Flickr


Carbon cover and bolts.

Carbon cover and bolts by Max Mutarn, on Flickr


DW Carbon Cover by Max Mutarn, on Flickr





Running tally = 150,617 grams.

Thats pretty cool Do you think it's possible to mould engine and front sprocket covers the same way? More layers of course, but it would save alot of weight.

[Shin-Ken 1074]

And they absorb some high pitched vibrations too

Yes, light weight and can help with absorbing vibration if needed.

[Shin-Ken 1074]

I always liked foam. Are they GrabOns?

Hi Rob, I have used Oxford Grab-Ons on other bikes however, these are Johar grips. I like the barrel profile and they hold up pretty well to use and UV exposure. I bought these a few years ago from a supplier in the States and wonder if they are still being made?


Johar grips by Max Mutarn, on Flickr