92 GSXR 1127 engine into 750F Katana, [sick]

[Buffalo Bill]

Finding time to work on these projects, not easy

OK, this is the middle of the summer riding season, sure is hard to take a bike off the road for a project.
This is my track day bike, I need to have room between track days to build and tune this swap.

Here are all the big parts going into the bike:

[Buffalo Bill]

They seem to be highly polished there, the rest of the cam looks like it has a coating of some kind.

in your pic it looks like the cams have a slight grove in the cams where the rockers ride. or is it just an optical elusion

[Buffalo Bill]

All the 1127s use a hydraulic clutch. I did not know that at the time but it makes sense to me.
I found a complete system with master cylinder, line and slave cylinder for $80, but the master cylinder needed a rebuild, another $30 for the kit.

My 82 GS1100G has a cable clutch, I replaced the plates and springs in it because they were slipping about 10%. Now it's a bear to squeeze.
The GS1100G only makes 66% of the power the 1127 makes, not even gonna think about using a cable clutch.

What are you doing for the clutch side on that 1127? Does the 750F cover fit so you can use the 750F cable clutch? Or are you going to get the hydraulic clutch setup?

[dorkburger]

Good heavens, that thing is tiny. Where does that shim go? Im guessing a pocket in the spring retainer?
Im unfamiliar with the breed....

[Buffalo Bill]

OK, washed it out with waste oil from my car.
Dropped the oil pan, a tray with screen over it, below the oil galley. Pored waste oil down the drain holes and cam chain.
The shim showed up in the screen.

[Buffalo Bill]

Can't get a magnet down there?

Nice idea, but those oil passages channel through external to internal steel tubes, the magnet would cling to the first part of the tube.
Besides, kingofvenus is right, I need to have a look see of the engine bottom.

Couple things I don't like so far, the oil residue left in the engine feels rather used up, like it was overdue for an oil change.
Plus: the bike was scrapped because the PO broke the chain.

[Fjbj40]

Can't get a magnet down there?

Well, at least this way you'll see the lower internals condition before you put it in her new home....

[Buffalo Bill]

Bummer, for the 1st time I tried taking a shim out. Easy to do because the rockers slide sideways out of the way.
Doh! Fumbled the tiny pill sized shim and it rolled down the oil return hole.
Looks like that's a quick return to the oil pan.
Now I gotta roll the 200lb lump over and take the pan off, just to fix a mistake.

Kids, be sure to stuff a wad into those return holes before you pull a shim out.

[Buffalo Bill]

Had time for an easy job, just checked the valve clearances, need 3 shims on #2.
Is there an easy way to push the springs down enough to change shims?
Got that answered already: with the lobes up, just push the rockers to the side.

This was the next generation engine after the GS. You can see here how much Suzuki improved their engine tops in every way; oil sealing, cam bearing caps, easy to work on.

If it were me, i'd leave the stock head on it for now if it's ready to run. Can always swap heads later down the road....

[Buffalo Bill]

No dots on the 1127, it's a GSXR.
My 750F does have dots.
Haven't opened up the 1127 valve cover yet.
Thanks for this info, I found some posts on the subject over at gixxer.com.

What year Katana? If it has the Dot head you should swap the heads and put the 750 Dot head on the 92 1127 motor and trash that shim head. They were known to spit shims when over revved. Plus the 750 Dot head will give it a nice bump in compression and fix the only flaw in the motor. The 91 & 92 1127 where the only air/oil cooled 1100 that had that design shim heads. They went to a different design in 93 when they mad it water cooled 1100.