My Kat rebuild

[GSX1100 dreamn]

Bandit dash mounted atleast for testing purposes for now.
I did silicone the upper housing to keep the water out

Cheers Andrew.

 

[GSX1100 dreamn]

So I have been running the EFI for a little while now and it has always had a FI fault.


As I was running the Kat dash I never knew until I connected the healtech interogator.


Had a cooling fan fault mainly because I wasn't running the cooling and I also hard wired the cooling fan relay for some accessories fair enough.


Now that I am running the Bandit dash 2 things happen.


1 the fuel gauge flashes constantly as there is no tank sender connected.


2 The FI light stays on and the odometer flashes with CHECK as well.


So to fix it I wired in the original cooling fan relay to the ECU to think it was there and added another relay to power the accessories.

Okay FI light out and I can now access the trip meter for kilometers traveled per tank.


Next I found the resistance values for the tank fuel level sender

Now I just had to replicate any of the values to get the dash to show a fuel level and stop flashing.


A relay I had with 27ohm resistance on the coil side was good enough to do the job.


Now I always have a full tank of fuel cool.

Cheers Andrew.

 

[GSX1100 dreamn]

I thought Kats didn't like water.

Two days riding in the rain and the dash/bike still works.

Cheers Andrew.

 

[GSX1100 dreamn]

Got the rear sprocket hub machined 3mm

centered the front sprocket 4.5mm + 5mm spacers

sprockets and chain seem to run centered

and nice equal gaps to frame and tyre

Need to order an offset front sprocket.
Cheers Andrew.

 

[GSX1100 dreamn]

With the fork extensions added and adjusted for Kat length 810ish

Cheers Andrew.

 

[posplayr]

A very simple check for chain alignment is to put a straight edge next to the rear tire and look for variation in distance to the chain. Of course this assumes your rear wheel is centered and aligned. In the picture i have a 3 foot construction level. This works best with wider/lower profile tires which have less runout of the rubber sideways. If you can get the straight edge against the wheel rim so much the better.

 

[GSX1100 dreamn]

Thanks Posplayr,

I will check and recheck particularly when I put all this onto my red Kat.

Cheers Andrew.

 

[GSX1100 dreamn]

The brake pivot is still a bit close even after shaving the tube and weld down

And I didn't want to chop the pillion tubes off for after market rearsets so the donor bike rearsets might be the answer and not run the Kat pivot at all initial test fit looks good.

Cheers Andrew.

 

[GSX1100 dreamn]

Easy cold starting so far.
Been starting to think about tuning the ECU to suit the motor and getting it fuelling better, but after 9 months of fault free running it can wait a bit more.
https://www.youtube.com/watch?v=21aK...ature=youtu.be
Cheers Andrew.


Cold
https://youtu.be/PJFmNC2QZSw
Colder
https://youtu.be/InNsqKeqvo4
Loving this EFI stuff, just turn the key and start and its good to go no hesitation cold or hot just go.
Anyway you get the idea.
Cheers Andrew.

 

[GSX1100 dreamn]

Now this is really the last time...


https://www.youtube.com/watch?v=IkuyiYQey7o


...for now.


Cheers Andrew.

 

[GSX1100 dreamn]

Then a post covid visit to the bakery after work,
first time in 3 months.
Sausage roll, small french stick and a appl chalotte.

Cheers Andrew.

 

[GSX1100 dreamn]

Strange but true...
...to get the starter to work I bridged the clutch lever switch and all is well and it has been that way since the conversion.

I decided to connect the clutch switch and see if it improved idle and 1/8 throttle a/f ratio seeing as there was an input to the ECU with the switch closed.


With the CLP wires bridged it pulls hard goes very well.


With the CLP switch functioning as it should it felt like a boat anchor has been chucked out the back, so much so I could accelerate with the switch off and then during the acceleration press the clutch switch (it was zipped tied to the handle bar) and it would lurch forward and pull hard and fast.


Switch wiring bridged and,


back to square one...mmm scratch head remove splinters and use to pick remaining teef.

 

[GSX1100 dreamn]

Getting real close to the Bandit suspension conversion.
That onto this,

New chain and sprockets

Offset front arrived

Chain guard shaped to fit

Clip ons

Money shot

Just hope after the mock up on the 750 Kat that the gearbox output shaft is in the same position as the 1100 LOL

 

[GSX1100 dreamn]

Fitted the 07 1250 Bandit suspension to my 82 Kat and a 650 Bandit Dash.

 

[GSX1100 dreamn]

Bandit red nearly Mazda red

 

[GSX1100 dreamn]

Bandit 650 Dash
Speedo healer coming

 

[GSX1100 dreamn]

The other side.

 

[Guest]

The level of detail and engineering on this build is astounding! Kudos.

 

[GSX1100 dreamn]

Thanks 80GS1000,
I am enjoying the modifications.
Although it has spiralled out of control once I got the donor bike.

 

[steve murdoch]

I believe you meant to say "the plan came together" when i got the donor bike.