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Classic Bike Trackdays

A Katana................in here................?????
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gagster55
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Joined: 04 Dec 2006
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Location: West Yorkshire

PostPosted: Thu Oct 29, 2015 1:47 pm    Post subject: A Katana................in here................????? Reply with quote

this is an on-going project that I have been collecting parts for - this is the starting point..........





you may think its the wrong place to post pictures of a (horribly coloured) GSX750S Katana frame, but bear with me. I have decided to combine my love of the big Katanas and 2-strokes by fitting a tuned GT750 motor into a suitably modified Katana frame - no USD forks / monoshock - it will run on twin shocks and rwu forks, but with modern-ish suspension, brakes and wheels.

after much research of Suzuki parts, I bid on a set of RF900 yokes on t'bay and got them for £10 + postage. They fit the Kat with no modification required - bearings and all - and they accept 43mm fork legs.



Then I dropped lucky with a pair of 43mm Triumph Sprint ST forks - the lowers need coating but the stanchions are blemish-free - only £60 including delivery Very Happy



with the RF yokes and Sprint ST fork legs in place...........





and with the Sprint ST front wheel I nabbed for £45 and a GSXR400 over-braced swingarm (that is now an under-braced arm) added........



need a look-alike rear wheel now (the Triumph runs a single-sided swingarm)..........

after much trawling of ebay I found this



a 2006 GSF650 Bandit (ABS) rear wheel, complete with disc and sprocket carrier, only £40 including postage Very Happy
The spoke pattern is as near as dammit the same as the Triumph front wheel I'm using and it runs a 160/60 rear tyre, which just fits snugly within the GSXR swingarm and won't make the bike look "over-tyred".
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gagster55
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PostPosted: Thu Oct 29, 2015 1:53 pm    Post subject: Reply with quote

here's some of the bits I have been hoarding for the Kat project, so I thought I would bolt them onto the bike so they are out of the way and I get to see what it might look like. First up, the front fairing bracket from Japan........



fitted........



the Triumph Sprint ST discs...........



and calipers, both courtesy of ebay.........



attached.............



the fuel tank.......



bit of damage to repair.........



sat in place...............



seat and tailpiece, both ex Yahoo Japan.........



and the component parts of the clock set that accompanied them.......



mounting bracket modified (still to finish shaping) and top yoke plate drilled and tapped to accept 6mm cap heads...........



some more...........

the LPM bodykit



great quality - easy fit - great service - looks good..........



GSX250S front mudguard..........



doesn't fit as-is because the tyre is too wide, but I have a cunning plan...........

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gagster55
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PostPosted: Thu Oct 29, 2015 1:59 pm    Post subject: Reply with quote

From Australia, a pair of Gazi suspension units...............



adjustable compression & rebound damping, preload and ride height gives me ample opportunity to f**k-up the handling........... Wink

Good old Yahoo .jp tempted me with this Paolo Tarozzi footrest kit.............





and the instrument pod, modified to take the Sprint ST electronic speedo - still work in progress - but it's mounted and just needs a new backplate making...........



TZR250 3MA under braced swingarm - £17 in Japan - £80 by the time it got to me. This is to replace the GSXR-400 arm which didn't work..........



not bad welding for a mass-produced item.............from Japan...........



and this arrived in the post - wonder what it could be...........?



after much deliberating, I opened it - voila..........



what a great invention...............wonder if it will catch on?

simple bit of engineering - I enlarged the upper rear engine mounting on the Katana frame.........



to take the (temporary) rear engine bolt......



which allowed me to try the GT750 engine cases for size.......



the cases just fit, lengthways, but there is plenty of room for the barrel and head.....



and clearance for the r/h.............



and l/h..............



header pipes

also made some mounts for the (Katana scooter!) 2T oil tank....



which is (mostly) hidden by the Kat's electrics plate.....



the electrics are for show only - new electrics and battery will be housed under the seat when the aluminium undertrays arrive..........
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The Cameraman



Joined: 22 Aug 2015
Posts: 608
Location: Lancashire

PostPosted: Thu Oct 29, 2015 4:01 pm    Post subject: Reply with quote

Hi Gagster55,

great start to a most interesting project.
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Howie



Joined: 18 Oct 2009
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Location: Kwaksville

PostPosted: Thu Oct 29, 2015 4:05 pm    Post subject: Reply with quote

Wow...........

I cannot wait to see this completed. A two stroke Katana Cool

Great touch using the Katana scooter oil tank Clap
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arlurt
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PostPosted: Thu Oct 29, 2015 8:15 pm    Post subject: Reply with quote

Really good to see interesting projects.

Keep up the good work!
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StrokerBoy
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Joined: 15 Nov 2006
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Location: Oop North, UK

PostPosted: Thu Oct 29, 2015 8:52 pm    Post subject: Reply with quote

Love your project threads, more of this kind of thing please. Cool
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Top-shaggy
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PostPosted: Thu Oct 29, 2015 9:17 pm    Post subject: Reply with quote

Brilliant stuff Smile
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Gillinghampaul



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PostPosted: Sun Nov 01, 2015 10:22 am    Post subject: Reply with quote

Loving this
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gagster55
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PostPosted: Sun Nov 01, 2015 3:41 pm    Post subject: Reply with quote

thanks guys!
awaiting a stash of parts from Japan, but meanwhile I'll get on with making some new engine mounting plates as none of the motor or frame mounts align with each other. Sad
The crank has gone off to SEP to be rebuilt and pegged (to stop it twisting) - necessary for a 90bhp + Kettle motor. Barrels are at Fahrons, having been rebored and ported to Suzuki factory TR750 spec (capable of producing 110 -120bhp). I may decide to use them for my track bike though - I reckon 70 -80 bhp will be enough for this project.
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nick69
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Location: Pontefract West Yorks

PostPosted: Tue Nov 03, 2015 8:47 pm    Post subject: Reply with quote

Epic as ever mate,really looking forward to this one Cool
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andyw114
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PostPosted: Wed Nov 04, 2015 7:43 pm    Post subject: Reply with quote

I think it was Performance Bikes magazine built up a Katana. They put in a frame brace to stop it flexing. That might be a good idea here.
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gagster55
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PostPosted: Fri Nov 06, 2015 12:31 am    Post subject: Reply with quote

collected the aluminium undertrays today, courtesy of Steve Adams / Lucky 7 Moto.

this one will house the bulk of the electrics and the battery.......



and this one will need a large hole driling in it for the 2-stroke oil tank filler neck.....



and fitted - no unsightly black plastic mudguard required now...... Very Happy



the parcel also contained a pair of bottom shock mounts..........



to be used to convert the mono-shocked TZR250 3MA swing arm to olde worlde twin shock spec.....

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The Cameraman



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PostPosted: Fri Nov 06, 2015 2:19 am    Post subject: Reply with quote

Beautifully engineered parts.
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gagster55
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PostPosted: Fri Nov 06, 2015 11:36 am    Post subject: Reply with quote

aren't they just.......... Very Happy
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