1981 GSX1100 Katana Based Project

[steve murdoch]

Come across many similar looking calipers over the years.
They also have a distinctive terrible smell.

[Shin-Ken 1074]

Popped the pistons using air, they were pretty tight, took 80 P.S.I. to get them out. Hold the caliper with the pistons facing down and a rag between the pistons and caliper body, prevents damage to the caliper body and stops the piston in the rag when it pops out under pressure.

F caliper 6 by Max Mutarn, on Flickr


The P.O.would have had a few interesting times trying to stop in a hurry with these brakes. I don't think these calipers were doing much stopping going by the amount of water and gunge in the bore, the pistons were jammed in pretty firmly!
F caliper 9 by Max Mutarn, on Flickr


F caliper 7 by Max Mutarn, on Flickr


Slide pin retainer growing a new crop of slime.
F caliper 10 by Max Mutarn, on Flickr


After hitting it with degeaser to remove the heavy gunge it's into hot water and detergent for the final cleaning with a soft natural fiber brush to prevent damage to the bore.

F caliper 12 by Max Mutarn, on Flickr


Now it looks like a brake caliper. Well it would if I took a decent pic in focus.

F caliper 11 by Max Mutarn, on Flickr

[Shin-Ken 1074]

Front calipers today. Bought a pair of used GSX 750F calipers for the project so it's time to strip/clean and throw a new piston and seal kit at them. Going by the internal condition Iam guessing the brake fluid hasn't been changed for a few years. Lucky the bores are not pitted so after a degrease and a wash in hot water and detergent the bodies look much better. With new pistons and seals fitted they should operate like new.

External condition not so bad.

F caliper 1 by Max Mutarn, on Flickr


F caliper 2 by Max Mutarn, on Flickr


F caliper 3 by Max Mutarn, on Flickr


Slide pins need a clean and repacking.
F caliper 4 by Max Mutarn, on Flickr


Slide pins cleaned.
F caliper 5 by Max Mutarn, on Flickr

[Shin-Ken 1074]

I guess I was going off my 11EZ weight of 567 lbs.

J I S - one of those things I was ignorant of when I got my first street bike at 18 and HAD to ride 100 miles every day.

J.I.S. screws with the single dot stamp really like their own screwdrivers, I don't worry about J.I.S. screws in general use however, carby screws I like to pamper with J.I.S. drivers.

[Shin-Ken 1074]

J I S man...

Careful how you spell that one Lorenzo!

[Rob S.]

Hi Rob, to have 150 pounds off would be fantastic however, the converter I used for kg to lb gave a figure of 104.8 lb.

I guess I was going off my 11EZ weight of 567 lbs.

J I S - one of those things I was ignorant of when I got my first street bike at 18 and HAD to ride 100 miles every day.

[Lorenzo]

Bought these screwdrivers about 10 years ago just for carb use only, they live in the study to keep them from being used as general purpose drivers, levers and scrapers.

J I S man...

[Shin-Ken 1074]

Carb cleaning time, not a complete strip down, that was done a few thousand km ago so it is just cleaning bowls, checking floats/pins and jets for varnish. Bought these screwdrivers about 10 years ago just for carb use only, they live in the study to keep them from being used as general purpose drivers, levers and scrapers.

carbs1 by Max Mutarn, on Flickr


Drivers by Max Mutarn, on Flickr

[Shin-Ken 1074]

Hi Folks, after having the Christmas and New Year holiday it is time to get back on to the build. Some wiring to sort out as well as finding out why the rear tail light doesn't work. Carbs still need some attention and perhaps re-jetting, will get on to that once the Kat is up and running after the wiring is finished. The identity of the front calipers has yet to be confirmed however, pretty sure they are 2004 750 F calipers. Have ordered one 750 F caliper re-build kit from Suzuki to see if they are in fact 750 F calipers, also included a rear master cylinder kit in the order.

Will strip and clean the calipers and check the condition of the bore in each this week sometime.

[Shin-Ken 1074]

184,446 grams = 406.6 lbs...that's light! That's dry weight, right?

That's more than 150 pounds you've shaved off. That's amazing!

Hi Rob, to have 150 pounds off would be fantastic however, the converter I used for kg to lb gave a figure of 104.8 lb.

[Shin-Ken 1074]

As of today the tally is 184,446 grams however, there are a couple of parts that could be modified and shave a few more grams off the current tally, and I mean only a few grams nothing more.

If the Suzi factory manual is accurate, it quotes the dry weight for a 1981 1100 Kat at 232 kg. So using the factory quoted dry weight of 232 kg as the baseline the build is at 184,446 grams which means 47.554 kg has been removed from a stock Kat.

The goal for the build was to shave 50 kg off because 50 kg was a nice round number and gave me a target to aim for and was based on my estimate of what I thought I could do to reduce the OEM weight. At 47.554 kg it has fallen short of the goal however, there are still a few things that could be done like a smaller flywheel and stator and a smaller starter motor. Parts, engineering and cost are the barriers to do these mods right now so they are not on the must do list at this stage.

The low hanging fruit as the Kat stands now are indicators, instruments and mirrors. By swapping these factory parts for lighter aftermarket parts there is 2kg to be saved however, one of the criteria for the build was to have the finished build look like a Kat and to do that factory mirrors, instruments and indicators are a must have so for now they stay.

I would like to think there will be some adjustments here and there so I am not signing off on the build at this stage. The engine has been run but it hasn't turned a wheel yet so there is still plenty to do, not so much with weight but other things to sort out before it is a road going build.


I need to go through the build tally to ensure all is above board with the numbers however, as of today the reduced weight of 47.554 kg = 104.8 lb.

Cheers.

[Rob S.]

184,446 grams = 406.6 lbs...that's light! That's dry weight, right?

That's more than 150 pounds you've shaved off. That's amazing!

[Shin-Ken 1074]

Have a few things to sort out before the big fella in the red suit turns up on Monday to share a beer and a few prawns so not much will be getting done on the build for the next few days.

Wishing everyone a Merry Christmas and a Happy New Year, keep the shiney side up and watch this space.

Cheers.

[Shin-Ken 1074]

Worn OEM rubber grip swapped for the new foam grip, 50 grams lighter.

foam grip twin by Max Mutarn, on Flickr

Running tally = 184,446 grams.

[Shin-Ken 1074]

Hi Steve, the Ti bolts look even better now they are on the Kat!

steel swapped for Ti by Max Mutarn, on Flickr

Replaced these steel bolts with Ti bolts and shaved 189 g from the tally.

Running tally = 184,496 grams.