750 Katana Resurrection

[KiwiAlfa156]

Squish clearance measured at 1.00 mm exactly. At least the stud will be easy to remove....

This one has obvious necking. I'll have to measure the others. The head had only one locating dowel fitted to position it on the barrels. I guess the tons of tension stopped anything from shifting. I can't tell you how many times I've cursed whoever butchered this bike. Then for the price I really shouldn't complain. I've been looking for evidence that the cases have split. So far no witness marks to suggest that the PO got that far. Hopefully no fresh horrors await.

 

[KiwiAlfa156]

Engine torqued into place. Next step correcting the steering head twist. Had to hammer the front engine mounting plates flat as they were bent. Was really pleased that all the engine mounts aligned which means my internal box jig worked as intended

 

[Nessism]

Impressive job. Thanks for sharing.

Keep going...

 

[allojohn]

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

 

[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.

 

[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!

 

[2BRacing]

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

 

[Grimly]

Excellent stuff.

 

[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.

 

[KiwiAlfa156]

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

 

[GS1150Pilot]

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

 

[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.

 

[Guest]

Great work, mate, keep it up!

 

[KiwiAlfa156]

Great work, mate, keep it up!

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

 

[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]

Thanks Fellas.

Doing bits and bobs

 

[salty_monk]

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

 

[Guest]

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

What region are you in?
I'm chasing some electrical gremlins atm but hope to be on the road soon

 

[KiwiAlfa156]

West Auckland, my friend. What are your gremlins doing?

 

[Guest]

West Auckland, my friend.

I'm out west, too

What are your gremlins doing?

Two cylinders not firing.
https://www.thegsresources.com/_for...gnal-from-(new)-Dyna-S-Is-my-ignitor-box-dead
But I think I got that sorted, fired it up just this morning and seems ok now. But the headlight no longer works