1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

Not in Australia mate, you'd lose your citizenship.

True, thanks for the back up Darryl, my shout next time.

Cheers.

[Shin-Ken 1074]

Time for the shocks to have a go. For twin shock rear suspension to operate at their best they should travel through the same vertical plane as the swing-arm and wheel. Given the wheel is 90 degrees when in the swing-arm that is two of three accounted for so the wheel is a good reference to use to install the shocks so they operate through 90 degrees and not at an off-set angle to vertical. These vintage pre-robot assembly line Kat frames were built by people and there can be slight variations and shock top mounts in some cases may need spacers to ensure exact shock alignment for both shocks. The third pic shows what size spacer will need to made for the left shock to be positioned in line with the wheel.

Shock 4 by Max Mutarn, on Flickr


Shock 5 by Max Mutarn, on Flickr


Shock 6 by Max Mutarn, on Flickr


Shock 7 by Max Mutarn, on Flickr

[Shin-Ken 1074]

Left shock spacers made today. Cut them from ally round tube, inner spacer and outer spacer are different I.D. and made from different O.D. tube to suit the shock top mount bolt.



Shock spacer 1 by Max Mutarn, on Flickr


Shock spacer 2 by Max Mutarn, on Flickr


Shock spacer 3 by Max Mutarn, on Flickr


L shock top spacers by Max Mutarn, on Flickr


L shock total by Max Mutarn, on Flickr

[Shin-Ken 1074]

Left shock done, now for the right shock.


L shock top by Max Mutarn, on Flickr


L shock by Max Mutarn, on Flickr

[Shin-Ken 1074]

Both shocks installed.

Right shock by Max Mutarn, on Flickr


Running tally = 159,570 grams.

[1978GS750E]

Interesting thread. Love what you've done so far! Looking forward to the finished bike.

Any idea how much has been reduced from your wallet on this build? Some of those parts look expensive!

[Shin-Ken 1074]

Interesting thread. Love what you've done so far! Looking forward to the finished bike.

Any idea how much has been reduced from your wallet on this build? Some of those parts look expensive!

Yes, at times the wallet has been a bit light on. The shocks were pricey but they are one part I never skimp on, riding is so much better with decent shocks. Nealy all the other parts are used and been found on auction sites or swap meets or from my pile of Suzi parts I have collected over the last few years when they were selling for very little money, unlike now.

Which parts look expensive?

Hoping to have the DW running in Dec. I'll be getting help from a mate to sort out the electrics and get her fired up, the dark art of elec-trickery is not my thing.

Cheers.

[limeex2]

Great project so far!

I saw the carbs were mentioned a couple couple ago, and it reminded me of my old GS450S. I replaced the stock carbs for ones from a 1st generation GS500 for pure performance gains, and was really surprised at the weight difference! I didn't have an accurate scale, but the GS450 carbs were easily a couple pounds heavier.

4V GS1100 carbs=7.7 lbs, GSXR flat slides=4.5 lbs. -3.2 lbs + H.P. gains.

[Shin-Ken 1074]

4V GS1100 carbs=7.7 lbs, GSXR flat slides=4.5 lbs. -3.2 lbs + H.P. gains.

Is 4.5 lbs the total weight of the flatslides including the twin cables and twin cable throttle assembly? Twin cables and throttle can weigh between 370 - 490 grams depending on if they are OEM or aftermarket.

[Shin-Ken 1074]

Why aluminium is your friend when your bike goes on a diet.


OEM peg, bracket and bolts.


OEM peg 1 by Max Mutarn, on Flickr


DW ally peg, plate and Ti bolts.


DW 180 peg1 by Max Mutarn, on Flickr

[Shin-Ken 1074]

DW ally pegs fitted.


DW peg 2 by Max Mutarn, on Flickr


DW peg 3 by Max Mutarn, on Flickr


Running tally = 160,073 grams.

[Shin-Ken 1074]

Lithium vs Lead acid. Lithium batteries may not be as bulletproof as lead acid however, weight is the name of the game for this project and when a lithium battery is 3,529 grams lighter than lead, then lithium is the go.

YB14LA2 battery by Max Mutarn, on Flickr


Lithium battery by Max Mutarn, on Flickr

[Shin-Ken 1074]

OEM coils, tough, reliable and last for years. No aftermarket coils need apply here.

OEM coils by Max Mutarn, on Flickr

[Shin-Ken 1074]

Relay/fuse panel has been installed after trimming the backing plate and swapping the screws and bolts.

OEM panel by Max Mutarn, on Flickr

DW panel by Max Mutarn, on Flickr


DW panel installed by Max Mutarn, on Flickr


Running tally = 160,800 grams.

[Shin-Ken 1074]

The SZ OEM wiring harness has been NLA for awhile however, Unicorn in Japan make a replacement harness for the SZ 1100 Katana. Happy Days!


Harness 1 by Max Mutarn, on Flickr


Harness 2 by Max Mutarn, on Flickr


Harness 3 by Max Mutarn, on Flickr