82 Kat resto-mod aka Project Bucket Case

[ukilme]

So, while I wait for new shocks mounts from Rob. I have been gathering other parts.

I just picked up a DID ERV3 520 chain which is the thinnest 520 chain on the market at 18.60mm. But here is Canada it can go for $200 or more. The cheapest prices I found was at http://www.bluestreakracing.ca/ base in Toronto or http://www1.petes-superbike.com/ based in Montreal. The price difference was 17 cents by the time you work in taxes and shipping. The chain it self was roughly $143cnd.

Now, if you go for a 520 sprocket and want to stay in Canada. Petes' can get the sprocket but email him first. Or order from your stealership and get them to order it from Steen Hansen Racing. Part number is 1825-48 for a JTR or 6050-48 for a PBI rear sprocket. PBI also has a 50t sprocket.

My front sprocket is coming from Rob.

I have also had some PMs with regards to the zrx 1200 shocks and some issues that may arise. IF you plan on using them ( posting this more if anyone ever searches for these shock).

1. They are 30mm longer then shock GS shocks.

2. This can be fixed by placing the bottom mount over the weld point on the B12 swing arm.

3. Placing the mounts over the weld will cause some more issues, you need a custom mount made with radius d cut (discussed a few post back) and need a 8 degree angle on the bottom as flat bottom will not work. This means it is a complicated/timely machining job and a little more costly.

4. The upper bushings on the shock are 14mm. This can be fixed by a sleeve or getting lower bushing and drilling them out. Not really a problem if you don't let it over heat and get the right drill bit.

5. THe zrx shock is 2.75" wide while Ohlins and Ikon are around 2.5 or less. This means possible chain clearance issues.

6. You can weld the left side mount to the edgeof the swing arm and gain clearance but now you shock will be about 5mm on the threaded part of the upper stud. And now looking at sleeves.

7. zrx shocks can go anywhere from 200-350 used and may still need a rebuild which is roughly 150-200 each.

Now, I am not saying it can not be done but I decided to cut my loses and go the tried and true route.

Currently, I am leaning towards the YSS.

 

[ukilme]

When I spoke with Rob, he mentioned and agreed with Jim that the sprocket side spacer should be .650" or 16mm which is the stock B12 spacer. He did also mention that there can be little differences. Now, mine is 3mm larger which is a lot. So, I decided to take off the rear tire and check the best I can with the rim. Rob also mention this is best.

Now, I do not have the tools to make the tools that Rob uses and posted earlier. However, I tried my hand at it and think it worked out.

The edges of the duct tape is the center of the swing arm, rods and front cross member(although the cross member wasn't really used). I then lined up a laser to hit the edges as seen it the picture. I did not even consider the rim when lining up the laser. Just the edges of the duct tape.

As you can see, the rear is pretty well center.

The rim is 159mm and center would be 78.5mm. Now, the measurement is a little off in the photo because I was taking a picutre with one hand. It was just shy of 80mm. Which means, I should have added 1-1.5mm to the stock 16mm spacer and not 3mm. However, I believe this should be fine.

This also makes sense as to why when lining the front wheel with the rear the left side measurement was 35mm and the right was 36mm.

 

[posplayr]

The rim is 159mm and center would be 78.5mm. Now, the measurement is a little off in the photo because I was taking a picutre with one hand. It was just shy of 80mm. Which means, I should have added 1-1.5mm to the stock 16mm spacer and not 3mm. However, I believe this should be fine.

This also makes sense as to why when lining the front wheel with the rear the left side measurement was 35mm and the right was 36mm.

79.5+79.5=159 mm right. You are closer than you think ??

If I remember I got 3/16" by just using a T square off the front of the pivot and a straight edge to the in side of each fork.

 

[steve murdoch]

A bit of a hi=jack here Andre, but did you see this swingarm for sale near you?
http://ottawa.kijiji.ca/c-cars-vehi...zuki-GS1100-Frame-for-sale-W0QQAdIdZ254423525

 

[ukilme]

Jim, I never even notice that. I screw my numbers up all time: phone numbers, house numbers and I even see words that are not there or do not see them. I think this is a condition I have...:-\\\

Steve, I have seen that a few times on Kijiji-and quickly thought about it- but the shocks aren't worth $600 and the swinger is not after market it looks to be just a GS swing arm with bracing. Thanks for the link-if you are interested and want to go look at it PM.

Anyways, I am leaning towards YSS for shocks right now. Still doing some research.

 

[Bad Kaw]

Progress? Love this one!
-KR

 

[ukilme]

Not much progress.

I had to paint a friends saddle bags, then I bought a 09 Sprint St and sold my CBF. And now I am helping my in-laws pack for their moving date coming up.

I did order YSS shocks and they took over a month to get here which was a hold up. I just got them today but the upper mounts were not what I ordered. Waiting to hear from them.

I did get Rob's shock mounts welded to the swing arm.

 

[Bad Kaw]

Heard back on your shocks?

 

[ukilme]

Ya, I actaully got working on the bike today. The first time in months. You gotta hate when you have a new bike.

I was able to get the Busa resets on, the shock bushings pressed into the swing arm and test fit the shocks. And then mounthe rear wheel to doulbe check the chain and shock clearance.

YSS sent the new bushing w/o a problem and had actually called within 3 hours of my email. Not bad.

I hope to have some picutres going by weeks end.

 

[ukilme]

Well, I have not forgotten my project. Simply put, I have been a 1 part busy and 2 parts lazy. So today, I figured I would do a little work on the bike instead of being jealous that some people got to ride while my bike is at the shop :angryfire:.

One small issue I had, besides the swingarm, was my steering stops. They did not allow enough movement from side to side. Luckily, there is no motor in it and I could just pick it up to turn it around. After cutting the stops back (what a pain), all is well.

I also got my swingarm modified, again, back in May to fix my shock mounts and move them back. I did use a different welder this time around. I also got shorter YSS shocks and sold the zrx shocks on Ebay-for a $75 profit.
Before:

Now: The mount hole are further back by 10mm or so and the shocks are 30mm shorter.

While getting the tank out, to check the stops, I figured 'what the @#!*% ' and take out some body work and take a shot. I did not put the front on as it would be a pain. If you look closely, you can see the difference between the gsxr clip ons and the cbr929. Also, the Buse rearsets on now on and the 'wings' are cut back.

 

[jwhelan65]

Curious, what is the rear shock length eye to eye or eye to clevis?

 

[ukilme]

340mm and they are adjustable by 10mm.

 

[ukilme]

JUst adding a note. Before starting a project like this, check your insurance in your area and see if you can get it covered or if the cost of coverage will work for you.

I am having a hard time. The project is not done as I will be painting the frame soon but this project might be dead in the water if I can not get insurance cheaper then I am finding.

I can still finish it and track it but I could sell the parts and pretty well break even. I will see in the next few weeks.

 

[Guest]

JUst adding a note. Before starting a project like this, check your insurance in your area and see if you can get it covered or if the cost of coverage will work for you.

I am having a hard time. The project is not done as I will be painting the frame soon but this project might be dead in the water if I can not get insurance cheaper then I am finding.

I can still finish it and track it but I could sell the parts and pretty well break even. I will see in the next few weeks.

How is your insurance company going to know its modified if you don't tell them? Does Canada's vehicle inspection process pick this up and report back to the insurance company? How the heck does Katman do what he does and find insurance in the great white north west? Are you trying to insure it with specifics so that they replace the aftermarket parts? Or are you just mainly looking for liability type coverage.

I never said anything to my insurance company about my modified E and when bike was rear ended they still factored in all the aftermarket stuff, course they were scared I was going to sue for pain and suffering. Things might have been much different if I was in a single vehicle incident where I was at fault.

I have a "don't ask don't tell relationship with my insurance company". Not that there is anything wrong with that.

 

[ukilme]

How is your insurance company going to know its modified if you don't tell them? Does Canada's vehicle inspection process pick this up and report back to the insurance company? How the heck does Katman do what he does and find insurance in the great white north west? Are you trying to insure it with specifics so that they replace the aftermarket parts? Or are you just mainly looking for liability type coverage.

I never said anything to my insurance company about my modified E and when bike was rear ended they still factored in all the aftermarket stuff, course they were scared I was going to sue for pain and suffering. Things might have been much different if I was in a single vehicle incident where I was at fault.

I have a "don't ask don't tell relationship with my insurance company". Not that there is anything wrong with that.

Here in Ont Canada. It will be classified as a classic at age of 30. This means only a few insurance companies will cover classics here. They all want/need an appraisal from their approved person- it means they know.

Out of the few-there appears to only be one that will cover resto-mods if done by a pro.

I am not worried about the suspension stuff-it's the 1100 in the 750 frame and frame mods.

Here in Ontario-insurance pretty well have us over the barrel. My company for my Sprint St does even like a after market shock

 

[ukilme]

Well, it look this project is dead in the water.

The insurance is a 'killer' so to speak. I know I could do it but at what cost to jump through hoops.

Also, I would rather spend the money on my Triumph ST suspension and airbrushing equipment.

So, all my parts are going to be up for sale and I post a list in the for sale section in the next few days.

 

[Roger P.]

Looks like I should be dumping all the Bandit/GSXR stuff I bought then. Unbelievable. The insurance a-holes got everything going their way in this province. My car insurance went up another $100, just because.

 

[ukilme]

Looks like I should be dumping all the Bandit/GSXR stuff I bought then. Unbelievable. The insurance a-holes got everything going their way in this province. My car insurance went up another $100, just because.

I would not do it just yet. I modified my frame and was putting a GS1100 motor into a Kat 750 frame. Insurance does not like that. SF will still insure the bike with just up graded suspenion from what I have learned.

I was thinking of tracking it but I really want to change out the springs on the Sprint ST and rear shock for my wieght.

I also had to pass up some motorcycle helmet jobs and a custom bike paint job recently because I did not have some equipment. This past week I took a custom football helmet job and had to source some things out. I said screw it. And this is just word of mouth as airbrushing and painting is just a hobbie.

So, my desicion is more then just insurance. It is multiple of things.