1984 Katana 7/11

[pete]

Haha yep Rob, right where I was told to be

[greg78gs750]

Lovely, Pete, congrats. Time to apply the whip to that beauty....lol

[pete]

Haha cheers Greg! Yep definitely need to get some km's done now, already just over 1/4 way to the first 1000km service

Ordered some 115 main jets yesterday which sounds way small, but given she was *way* too rich with 122.5's I think it's the right direction, hopefully I can get some time this weekend to get the throttle open again although it's supposed to be wet...

[Loccoli]

Nice one Pete! Sounds awesome! I hadn't been on here in a while and it put a smile on my face to come in and see your beast on the road. Come down to Melbourne and I'll get some nice pics for you in exchange for a spin

[pete]

Hahaha cheers mate! Definitely on the bucket list to get down to Phillip Island on two wheels for either MotoGP or WSBK one day so you never know

[angrypants]

wow what a thread, what a build, what a bike, congratulations Pete

[pete]

Cheers mate! I'm really enjoying the end result i can tell ya'!

I'll get one more ride out at some point this weekend when it'll be time for the first service, then it'll be just ride and enjoy.

[thebrandonbeezy]

Look's stunning pete! Glad to see it going

[pete]

Cheers mate! Me too

[zuluwiz]

Shall we all just assume you've been much too busy riding to chat here? (I sure as 'ell would be) Just one question: Have you named your Kat?

[pete]

Well... yeah, will have to share post first service pic's I guess

I've been pretty slack at getting pic's while out and about, and I still owe you lot a BOM worthy pic as well.

Things I definitely need to do are replace that oil plug again as the leak is back to as bad as it was so my dodgy fixes that worked initially no longer work (not surprised) and replace the hand grips. I got some foam grips but they're different to what I'm used to and must be crap quality as after this short time in use I can already see indents from my fingers in them and they're quite uncomfortable. I've got to shop around for some better alternatives.

I had an issue with brake fluid spraying up the rear of the bike while riding (so glad I went silicon based DOT5!!) but I managed to solve that by replacing the rear master reservoir. My repair of the cracked post with JB Weld didn't work so well as the thread stripped out, meaning the lid was able to move up enough for air pressure to suck a bit of fluid out. There was brake fluid between the cap and the rubber diaphragm which should never be there.

As for a name... it's just "the Kat" at the moment, never really named my bikes. The 450 is known as "the 450" or when out with the Katana boys "the wee beastie". I'm not that imaginative

Oh, I have still yet to get better fueling, primarily I believe due to having the wrong throttle valves in the VM33's. Low throttle positions aren't great and I've had to compromise a lot with the air screw and idle setting to get it to idle at all. I have 1.5's in there now but by all accounts GSX motors need 2.0 throttle valves which are NLA, so I haven't decided on a plan of action there just yet. The 1.5's can be modified to 2.0's but that's a permanent change so there's no back to back testing possible. Still rich up top on the mains despite dropping from 122.5's to 115's but that's an easy fix, and I probably need 110's to sort that out.

[pete]

Well bugger, out for a very enjoyable ride Saturday morning and when we pulled up at the cafe for brekky noticed a whole heap of oil over the rear of the seat, chain guard, shock, dripping on the ground, and the very left edge of the rear tyre. Concerning! I couldn't see anything around the motor anywhere and we deduced it was the left Koni shock. The stanchion and all around it were wet. Tied a handkerchief and a bit of paper towel around it and rode very carefully home to avoid the oiled left side of the tyre.

I pulled it apart Saturday night and gave it a once over last night.

I tried replicating the oil leak on the shock, but even upside down it won't spit any oil out, however I suspect that's more likely due to a lack of oil than anything.

I believe I found the culprits though...

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

Three decent sized pits in the stanchion that I obviously missed were there when rebuilding the shocks. One has a bit of a jagged edge to it, and they're right up near the bump stop which would explain why they haven't caused me issues sooner.

Need to figure out where to from here, just throwing new seals in won't prevent a recurrence that's for sure!

[windcrow]

Hi Pete! Been following your work a long time. Awesome workmanship!
That stanchion should be repairable. I would try carefully filing the pit with the jagged edge with a good clean fine-toothed file, then fill the pittings with JB-Weld. Buff with 2000-grit where needed. This method worked on a set of forks I rebuilt. YMMV. Then again, there's https://www.ikonshocksusa.com if you have to get new shocks.

[alke46]

Wow, close call. Good thing some of that oil didn't end up on the edges of the tire. The next corner or sweeper might have caused a bit of discomfort.

[pete]

Oh there was oil on the tyre alright Larry! About a half inch all the way around the left edge. Fortunately it looks like that was after the tight twisty bits otherwise that would've been rather interesting indeed!

Windcrow, cheers for the tip! I lucked out and a mate has another set of Koni's which I picked up last night and while they need a rebuild the stanchions on both shocks look to be in good shape, so I should be all set now. Will definitely keep that in mind though!