750 Katana Resurrection

[salty_monk]

Looking good! Probably straighter now than when it left the factory...

[KiwiAlfa156]

Thanks Fellas.

Doing bits and bobs

[Kiwi Canuck]

Thanks for posting on GSR, brings back some memories for me, several of the bikes I've restored have had similar issues, many broken and stripped bolts/screws, bent rear sub frame, all the usual fun stuff.

Even though it's frustrating at the time, it brings so much enjoyment when you are able to fix all the issues and get the bike back to how it should be.

Carry on, looking forward to your next installment.

David.

[KiwiAlfa156]

Great work, mate, keep it up!

Thanks! Look out for it on the streets when she's finished

[psyguy]

Great work, mate, keep it up!

[KiwiAlfa156]

I think I know how this Kat got bent....



I'm sure the POs brakes didn't squeal, but his butt certainly would have when he grabbed a handful of drip lubricated brakes and bugger all happened.

And yes the brake pins had been tightened to about 500 ft-lb requiring a piece of pipe on a breaker bar to loosen. How the anti-squeal shim got stuck in the top of the caliper is anyone's guess.



On the bright side the pistons and seals are in excellent condition. The fork oil had rotted the sliding pin dust boots, but the piston dust boots were intact.

[GS1150Pilot]

This thread is inspirational. I really need to get back to restoring my '82 CB900f.

[KiwiAlfa156]

Frame finished in silver. Tyres ordered. Next step, rolling chassis assembly.

[KiwiAlfa156]

Final confirmation of alignment. Checked the rake measured at just under 28° while sitting on the rims. So very close to the 28.5° GSX750S spec.



Some of the factory welding on the frame was really bad. Either the frame welder had a hang-over or they were a beginner. Holes aplenty. The arc welder was handy, and setting up the MIG seemed an unnecessary hassle. Not perfect, but better than what was there.




Loose paint and surface rust removed prior to rust treatment and etch priming.

[Grimly]

Excellent stuff.

[2BRacing]

Wow, very impressive work, well done! The PO really did a number on that engine!

[KiwiAlfa156]

Lockdown has meant I couldn't get some cones made up for the steering head so I had to improvise. The pitted fork stanchion was almost a perfect fit through the steering head but it fouled the internal lug of the steering lock. I don't have key for it, so I cut back with a half round hand file. I left the bearing races in to spread the force to the steering head. If they got damaged, they're easy to replace. Put an extension pipe on the tube and started the untwisting.



The amount of deflection required made the dial gauge redundant. So I went incremental, doing a little more deflection each time, putting the forks back on and checking the front axle centre spot against the centreline reference marks on the frame/rear wheel. And a after an hour or two, great success!

[Rich82GS750TZ]

And thank you for posting good, clear, big photos. Many don’t take the little bit of extra time to set up an account on a pic hosting site that they use to link the photos. It is very much appreciated.

[allojohn]

Jeez, a lesser man would've found another example to restore. Some serious knowledge on display here...

[Nessism]

Impressive job. Thanks for sharing.

Keep going...