Smokin's 82 Kat Restorification project

[Macguyver]

Aren't bikes fun?

Looking good man. Keep it up!

 

[cavehamster]

I'll remember to put stuff in the top half on mine. My paint finished up this weekend, I hope to assemble it this week.

 

[Smokinapankake]

Thanks Mac, I'm glad to have that half done....

I'm a little concerned about the engine paint, tho. I cleaned the cases really well in a solvent tank and then parts washer, repeating the cycle about 4 times.
Then I used Dupli-color engine paint, low-gloss black. Didn't post cure bake them so I'm hoping the paint will hold up... Any thoughts/input?

 

[spyug]

Very understanding wifey you have there assembling the engine in the family room right on the coffee table. I get weird looks even when I'm doing things like that in the man cave.

Yup this bike resto is a slippery slope. I'm not as bad on this one as I was on the XS build however. I've learned to curb my" want it.....got to have it" impulse. This time I'm shooting for clean, tidy, safe and functional, no performance mods other than the quick turn throttle tube ($15). Even with a tight fist on the wallet I have already shot passed the $1500 budget but I'm getting close on finishing so hopefully not much more will be sunk into it.

Careful with the engine paint as it will be affected by gas and oil until it has been heat cured. I ruined mine when some gas shot out of a carb as I was attempting to fire it up. Put some halogen work lights on it for a few hours that will help some.

You are doing a bang up job and this is an entertaining read so by all means take your time and let us savour it all. You know we all like to live vicariously through others, what a bunch of wonks we are:-\\\

Cheers,
spyug

 

[Macguyver]

Need a little heat!

Need a little heat!

You know we all like to live vicariously through others, what a bunch of wonks we are:-\\\

Hey! I resemble that remark...oh wait, crap. :lol:

+1 of the halogen heat lamp idea. Anything we can do to make that paint more resistant is a plus. Baking would be ideal to get all of the solvent out of it, but do what you can to heat the engine. Maybe a space heater blowing at the bottom of it, since heat rises, you might be able to get a semi-bake going if you can get enough heat to it.

I don't recommend a salamander heater. Don't ask me how I know. rassa frassin fricka fracking co-op students! grumbe grumble

 

[cavehamster]

Thanks Mac, I'm glad to have that half done....

I'm a little concerned about the engine paint, tho. I cleaned the cases really well in a solvent tank and then parts washer, repeating the cycle about 4 times.
Then I used Dupli-color engine paint, low-gloss black. Didn't post cure bake them so I'm hoping the paint will hold up... Any thoughts/input?

As long as you got all the grease, oil, and loose bits off the engine first, the paint should stick. I was a tad paranoid on mine, I jet washed the block, degreased it, hit it with walnut shells out of a sandblaster, shot it with brake cleaner to get anything left, then some aluminum etching cleaner, an epoxy sealer/primer, before finally putting on a coat of black bbq high temp paint on it. We'll see if I have any luck with it staying on too, hehe.

 

[Smokinapankake]

Thanks for the encouragement fellas, your positive vibes help me stay motivated!

I wondered if anyone would mention the coffee table/family room thing. Only comment she made was that she's "glad she doesn't care about the coffee table". She's wonderful for even letting me consider rebuilding this motorcycle. Especially after the grief I got when I bought the 84 750!

I hear ya loud and clear Spyug on the resto thing. I'm fighting the urge to splurge on a stainless bolt kit! Speaking of which, I'm looking forward to seeing some photos of your Kanotuna!

I may try directing some heat from a portable room type heater at it; at this point there aint no way it's going into the oven (or barbecue for that matter) for a bake out. I figure running it around oughta be like a bake out, eh?

At the worst, if it starts chipping and peeling it'll be two tone engine paint! Back in the 80's crackle paint was very popular on bicycles..... Try that on your resto! Besides, I'm never doing this again. So we'll just have to see what happens, right?

 

[Macguyver]

At the worst, if it starts chipping and peeling it'll be two tone engine paint! Back in the 80's crackle paint was very popular on bicycles..... Try that on your resto! Besides, I'm never doing this again. So we'll just have to see what happens, right?

Aw, c'mon, half the fun is having to paint everything twice! :lol:

I would think the first run should do the trick. I keep having a thought rattling around in my head that engine paint should be baked in the first 24-48 hours...:-k I can't remember where I heard that though.

I know I wouldn't want to have to pull everything apart again to bake it , so I completely understand the "let's wait and see" attitude regarding the engine paint.

As always, great work, keep it up!

 

[Smokinapankake]

Hopefully its not the first 24-48 hrs. This thing has been sitting on a shelf in my basement for 2 years now. Prolly out of that time frame, I bet:-\\\

Thanks for the encouragement and the feedback about my stupid ideas - they keep me on track.

One other thought Spyug - She didn't even bat an eye when I proposed to assemble frame, suspension, and wheels into a rolling chassis in the entryway. My argument was that everything was clean and new; she said "sure, why not?" Gotta love a woman like that!

 

[Smokinapankake]

Again, a little progress!

Again, a little progress!

But sadly, no photos. Unless you wanna see some pics of ringsets...

Just ordered some piston ring sets from Babbitts online to the tune of about 140 bux including shipping and a few other little things.
Its always the little things that add up.

I'd decided that, although the Katana fund is overdrawn, if I don't get this motor together the whole thing will never go together.

SO, once that is done it becomes a matter of carbs (which are already tuned - just need cleaned), bodywork, and installing the wiring harness. Granted, there are several mini steps encompassed in each of those big ones, but I think I see a very very dim light at the end of the tunnel (or is that just my own reflection in the mirror - you know, dim being most appropriate)!

 

[Smokinapankake]

Piston Ring sets have arrived!

Piston Ring sets have arrived!

After what seems to me an inordinately long time. Babbits won the price war, but lost for delivery time. I'd probably order from them again, tho.

So, even though I had all that time while waiting for rings to come, I didn't hone the cylinders or lap the valves. Dummy me, but now that needs to be done afore anything else happens. Hmmm, when will I find the time to do it?

Yeahm,

 

[Smokinapankake]

Piston Ring sets have arrived!

Piston Ring sets have arrived!

After what seems to me an inordinately long time. Babbits won the price war, but lost for delivery time. I'd probably order from them again, tho.

So, even though I had all that time while waiting for rings to come, I didn't hone the cylinders or lap the valves. Dummy me, but now that needs to be done afore anything else happens. Hmmm, when will I find the time to do it?

Yeah, yeah this project has slowed wayyyy down from the early stages. So sorry sports fans, but my time is at a premium right now so be patient.....

 

[spyug]

Hey don't I know about projects slowing to a crawl.

About a month back I got involved with helping a young lady buy her first bike (GS400 documented elsewhere herein) and agreeing to teach her to ride safely on the street ( she took the course last year).

Since finding the bike, it was decided it was the wrong colour so our hero "volunteered" to repaint it. Big mistake, that paint job is kicking my ass ( also documented elsewhere herein) and the trainee is getting bugged about missing lessons (its been over a week now and I still have to repaint and clear the tank).

There have also been house projects ( new floor still unfinished after 2 weeks) and business is steadily improving and going off on new tangents.

The Kat project is languishing. I have the base coat down and the decals ready to go on but I was planning on clearing it all over the long weekend with the stuff from the 400. Didn't happen, of course.

There's a big bike show this weekend coming so Saturday is already written off. Sunday is a ride day as they're calling for good weather again and next week I have to finish floor before the boss gets back from Florida holidays.

No rest for the wicked and no time to vinish the Kat Diamnnnnnnnn

Hope you can get those rings in and that mill buttoned up sooner rather than latter.

Cheers,
Spyug

 

[Guest]

So, even though I had all that time while waiting for rings to come, I didn't hone the cylinders or lap the valves. Dummy me, but now that needs to be done afore anything else happens. Hmmm, when will I find the time to do it?

I have just this past week lapped the valves back into my freshly painted head... then I re-installed them (along with new valve stem oil seals).

This was my first time doing this task & my God, you need the hands of a surgeon to get all those little valve spring "keepers" back into place!

Good luck with process - hopefully you're better & quicker at it than I was - took me about 2 hrs to get 'er done.

Mike

 

[TheCafeKid]

I have just this past week lapped the valves back into my freshly painted head... then I re-installed them (along with new valve stem oil seals).

This was my first time doing this task & my God, you need the hands of a surgeon to get all those little valve spring "keepers" back into place!

Good luck with process - hopefully you're better & quicker at it than I was - took me about 2 hrs to get 'er done.

Mike

Not to highjack but Mike, next time, use a little bearing grease as "glue" It will hold one side on, while you put the other in place. Do it that way, will cut your time in half.

 

[Guest]

Not to highjack but Mike, next time, use a little bearing grease as "glue" It will hold one side on, while you put the other in place. Do it that way, will cut your time in half.

Hey Josh,

I did use grease, but it still took me quite a while to complete the job - those 16 valve engines take some patience!

However, my home-made valve depressor (modeled after Steve's version) worked like a charm.

 

[TheCafeKid]

Hey Josh,

I did use grease, but it still took me quite a while to complete the job - those 16 valve engines take some patience!

However, my home-made valve depressor (modeled after Steve's version) worked like a charm.

Yeah the 16Vs are a little tighter to work in. Plus you have double the valves. I use a compressor Steve made for me as well! They absolutely do work like a charm, and cost a 1/4 of what an actual tool would cost..

 

[Smokinapankake]

Thanks for the encouragement and patience, guys, but to be honest, I'm a little intimidated about putting the top half back together. This is probably half of what's stopping me right now. Combined with the urgency to rebuild my deck before it gets too bloody hot, Saturdays riding bikes (bicycles) with the kids, and a basement family room in dire need of mud and tape, well, the Katana falls to about last slot on priority.

Add in that I have the 84 750 to bum around on, my motorcycle jones is fulfilled somewhat that way.

Have any of you lapped valves and what does it involve?

 

[wesmoon]

any updates?

 

[Smokinapankake]

Funny you should ask, wesmoon,

I've scheduled this coming Friday the 28th (even though the 30th is my 12 year anniversary, and I work Sundays) to have my buddies Matt and Tim come over and button up this bloody motor.

Matt is the shop supervisor at a local Victory Cycles dealership, and has built hundreds of motors over his career. Tim, Matt's brother in law, is a hard-core drag racer, V-max ridin, crew chief for a pro-stock drag car based in Salt Lake City. Tim is also parts manager at the local Honda (cars) dealership in Salt Lake. Tim has had his hands in more than his share of motors, although they be of the V-8 persuasion.

I'm confident that between the three of us we'll be able to accomplish that which has stalled me (solo) for months now.

The deck is semi-finished, the basement has been put on hold due to the deck, and since my work schedule has been reinstated (Sun-Wed), wifey said "go ahead and get that thing done".

Many many pics to follow!

PS - I've got the following in hand in preparation for the reassembly:
Hone
assembly lube
all gaskets and O-rings
Matt uses plain ol' motor oil for the hone operation
lapping compound for valves
valve lapper handle tool thingy with suction cups on the end...
Matt has ring compressors

Need: to formulate some sort of valve spring compressor. Pics of some homemade versions would be helpful. Or, alternatively, I may be able to borrow one from a fellow enthusiast at work, if he has one. I'm thinking if I fabricate one it will be along the lines of a big C-clamp with an "adapter shoe" made from brass or plastic (PVC?) tubing with access windows cut in to insert the spring retainer keepers. Hate to buy one for a one time use and I don't know anywhere I can rent one of the correct configuration/size. Granted, I haven't looked around anywhere either.

Anything else I may need? We're planning on putting the cylinders back on, reassembling the head - this means lapping and installing valves, installing and timing the cams - and installing the head.

Thanks for the help and encouragement, folks!