Hi Folks, hhhuuuummmm, a Katana based project eh, what is that exactly? O.K. let's go. First thing is I am in Australia so this project is all about the Oz flavored version of the 1100 Katana.I have owned and ridden the glorious 1100 Katana since they were released in Australia in 1981 with my current (2nd) 1100 Kat having been my ride for the last 37 years. This Kat was BOTM back in Nov 2011.
I love the Kat and everything about it, until recently! Injuries and wear and tear on the body over the years have finally caught up with me and the 232 Kg dry weight of the Kat is becoming a not so enjoyable aspect of the riding experience these days. How to own a Kat and keep smiling without popping a lower back disc when its time to push it around in the shed or when out and about? Make her lighter, and me as well while Iam at it.
I have spent a bit of time thinking about how to go about shaving 50 kg from the Kat and still have her look like a Kat (you may have to squint a little bit when up close.) and not a highly modified custom machine. So I am at the beginning of the build and will start to post pics and info about the project soon.
What is a project without a name? The name for this build is DW180. As my current Kat is a stock survivor 1100 Kat, that will not be the donor or contribute in anyway to DW180. To kick off the project in April 2021 I had an Oz 1981 1100 Kat frame, it started with just the frame and nothing else. Since April 2021 I have been planning and tracking down parts and now it's time to begin bolting the project together. Some ground rules I set for myself for the DW180:
No radical angle grinder or hacksaw surgery, trimming and shaving sure, but nothing along the lines of cutting off the rear foot peg mounts or the centre stand lugs.
Must retain stock indicators and clocks and genuine Suzuki mirrors.
Suzuki wheels, not the stock 19" front 17" rear snowflake. DW180 wheels will be cast ally 1985 GSXR 750 18" front and 18" rear. These are slightly lighter cast wheels compared to the snowflake Kat wheels and being Suzuki they look right. Being a tubeless rim, lighter radial tyres (and deleting the inner tubes) can be fitted to replace the tradition bias type heavier Speed Demon rubber that quite a few Kats are shod with.
There will be changes that are not visible like aluminium axle and bearing spacers and titanium bolts as well as the very visible stuff like 520 chain/sprocket set up, carbon chain guard, hollow axles and pivot bolt, hollow chromemoly clip-ons with aluminium bar weights, lithium battery and various Suzuki parts like the RG500 aluminium gear selector. Titanium pipes and muffler with aluminium flange clamps and Ti bolts.
Replacing the side covers, seat and ducktail with a one piece solo seat unit made of fibreglass, no need to buy a seat, ducktail or expensive side covers.
The stand out non Kat part of the build will be the engine, the power plant will be a 1985 GSX 1135 EF engine, 3.2 kg lighter than a GSX1100 stock engine with 14 extra horses, win,win!
I don't have a workshop just a shed and the budget is pretty thin so parts are mostly used Suzi with a few hand made parts here and there as well as plenty of filing to reshape parts. Trying not to go the "drill it to Swiss cheese path" where I can. Some drilling but not everywhere as pics will show.
The frame has been painted and so it all begins very soon.
The disclaimer. This project is exactly that, a personal project and all information, photos and details presented here are for my personal interest as a hobby. Everything associated with this project and presented here is for entertainment purposes only and not a guide or endorsement in any way of using and modifying a motorcycle or motorcycle parts. Any aftermarket parts, modification or fabrication of parts and the installation and use of any and all parts have not been tested or approved for use on a motorcycle on a public or private road, place or venue of any kind. My project, my risk.
Cheers,
I love the Kat and everything about it, until recently! Injuries and wear and tear on the body over the years have finally caught up with me and the 232 Kg dry weight of the Kat is becoming a not so enjoyable aspect of the riding experience these days. How to own a Kat and keep smiling without popping a lower back disc when its time to push it around in the shed or when out and about? Make her lighter, and me as well while Iam at it.
I have spent a bit of time thinking about how to go about shaving 50 kg from the Kat and still have her look like a Kat (you may have to squint a little bit when up close.) and not a highly modified custom machine. So I am at the beginning of the build and will start to post pics and info about the project soon.
What is a project without a name? The name for this build is DW180. As my current Kat is a stock survivor 1100 Kat, that will not be the donor or contribute in anyway to DW180. To kick off the project in April 2021 I had an Oz 1981 1100 Kat frame, it started with just the frame and nothing else. Since April 2021 I have been planning and tracking down parts and now it's time to begin bolting the project together. Some ground rules I set for myself for the DW180:
No radical angle grinder or hacksaw surgery, trimming and shaving sure, but nothing along the lines of cutting off the rear foot peg mounts or the centre stand lugs.
Must retain stock indicators and clocks and genuine Suzuki mirrors.
Suzuki wheels, not the stock 19" front 17" rear snowflake. DW180 wheels will be cast ally 1985 GSXR 750 18" front and 18" rear. These are slightly lighter cast wheels compared to the snowflake Kat wheels and being Suzuki they look right. Being a tubeless rim, lighter radial tyres (and deleting the inner tubes) can be fitted to replace the tradition bias type heavier Speed Demon rubber that quite a few Kats are shod with.
There will be changes that are not visible like aluminium axle and bearing spacers and titanium bolts as well as the very visible stuff like 520 chain/sprocket set up, carbon chain guard, hollow axles and pivot bolt, hollow chromemoly clip-ons with aluminium bar weights, lithium battery and various Suzuki parts like the RG500 aluminium gear selector. Titanium pipes and muffler with aluminium flange clamps and Ti bolts.
Replacing the side covers, seat and ducktail with a one piece solo seat unit made of fibreglass, no need to buy a seat, ducktail or expensive side covers.
The stand out non Kat part of the build will be the engine, the power plant will be a 1985 GSX 1135 EF engine, 3.2 kg lighter than a GSX1100 stock engine with 14 extra horses, win,win!
I don't have a workshop just a shed and the budget is pretty thin so parts are mostly used Suzi with a few hand made parts here and there as well as plenty of filing to reshape parts. Trying not to go the "drill it to Swiss cheese path" where I can. Some drilling but not everywhere as pics will show.
The frame has been painted and so it all begins very soon.
The disclaimer. This project is exactly that, a personal project and all information, photos and details presented here are for my personal interest as a hobby. Everything associated with this project and presented here is for entertainment purposes only and not a guide or endorsement in any way of using and modifying a motorcycle or motorcycle parts. Any aftermarket parts, modification or fabrication of parts and the installation and use of any and all parts have not been tested or approved for use on a motorcycle on a public or private road, place or venue of any kind. My project, my risk.
Cheers,
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