Katana 400 intervention begins [Archive]

James Deuce

4th June 2007, 19:02

NM came over this afternoon and we dismantled the front end.

Everything came apart OKish and there were only a couple of things that ended up burred due to age and corrosion.

The fork seals were indescribable. Even the circlips were corroded and the fork "oil" was a light grey coloured mud. There was also significantly more than 150mls per fork leg too, more like 400mls per fork leg. The dust seals had turned to concrete as well and looked like someone had tried to butcher them at some point.

The steering head "bearings" - well um what can one say. The lower bearing's case collapsed during removal. The top one still had the factory grease and it had literally turned to rubber.

Off to Scroederco tomorrow to get steering head bearings, and a bottom fork allen bolt (the internal one) that that rounded off during the removal.

Oddly the wheel bearings were good.

Here's some photos of stuff boxed up to go out the door and a bike precariously balanced on a jack and some concrete and wooden blocks.
Managed to get most of the petrol out of the tank and into a container so I can use it again. Drained the carbs too.

psyguy

4th June 2007, 21:37

a bike precariously balanced on a jack and some concrete and wooden blocks.
nice!

seriously, good job so far, make sure to keep us updated, looking forward to it!
and best of luck with the project!
:rockon:

Pussy

16th June 2007, 21:56

How's the restoration going, Jim? Got the forks back from Hamilton yet?

James Deuce

16th June 2007, 22:07

There's some plastic collars in the forks that no one can get out. The Hamilton guys won't attempt the re-chrome until the collars are out and fair enough.

Taking them to Graham Berry racing to see if they can do something. I've had the fork legs cleaned up in the event I can't get the collars out and I have to hunt down some better condition stanchions or forks. That way I can at least ride the bike and replace fork seals as necessary.Starting to look like an excuse for grafting a late model GSXR400 front end on.

So far I have sorted top steering head bearings, oil seals, dust seals, air filter, a replacement for the fork leg lower allen head cap bolt I had to "encourage" out of its thread, and the painting starts this week. MSTRS has set me up with the decals and crazefox is doing the paint. I've got the original fork springs from the Z750 to try in there as well.

Have to take the steering stem off tomorrow and try and get the lower steering head bearing race off.It's a bit stuck.

Skunk

16th June 2007, 22:13

Have to take the steering stem off tomorrow and try and get the lower steering head bearing race off.It's a bit stuck.
Gas plant reqd?

James Deuce

16th June 2007, 22:15

I'll take you up on that.

Dadpole

17th June 2007, 00:17

I found a quick way to get off the lower race is to give it a touch with a MIG or arc welder. Heats and expands it, but not the steering stem then it should be able to be drifted off. If all else fails, careful use of an angle grinder and a whack from a cold chisel will put a crack in it, then Beryl's your auntie.

F5 Dave

18th June 2007, 17:55

Give us a yell if the lower stem is still giving you grief. Above methods work well with care.

James Deuce

3rd July 2007, 19:16

Dust seals and air filter have arrived.

I have discovered that the forks are indeed the same as a Bandit 400, so it looks like I'll be getting new sliders as the appear to be only $2 dearer each than the re-chroming process was going to cost.

All I need now is a suitable drift to get the bearing cases out of the steering head, and the lower race off the stem. I could try violence, but I think I'll be going with F5Dave's suggestion of yelling at him. I've seen him remove screws with no visible means of screwdriver interface, so I'm sure a couple of stuck bits and pieces will be no trouble.

I've been spraying every bolt, screw , nut and threaded surface I can see with CRC, every time I do something on the bike. It is starting to pay off as I've been able to remove things that wouldn't budge a month ago.

MSTRS has sent me the decals, and I've dropped the tank and fairing off to crazefox for painting. We've gone with the smaller "SUZUKI" decal that's been done in the same sizing as a TL's tank logo. They're white rather than black, but I think it will modernise the look a little without detracting from the overall theme. In fact I think it will look a little classier.

Only thing left to do now is get the exhaust system looked at.

limbimtimwim

3rd July 2007, 21:14

James Deuce

3rd July 2007, 21:32

Blimey! My long term plans have been uncovered!

Already replaced the rear tyre with a Sport Demon.

The shocks will be getting a rebuild soon. The front subframe will be off for a powdercoat by Christmas.

The Frame will probably get a strip down and powder coat next Winter :)

I like being doomed.

Oh yeah.

He has a name now. Ken the Katana. His nickname is K'erst

F5 Dave

5th July 2007, 10:34

Well you have my number.

James Deuce

5th July 2007, 11:32

Fork legs will be here in "2 weeks" ex-Japan. Mind you the dust seals and air filter only took 10 days.

I do indeed have your number. I will call soon. Don't let me interrupt your project though, Mr F5Dave.

El Dopa

5th July 2007, 21:03

And then after that, maybe rejet the carbs, oh, what the hell, flashy rear shocks, just some emulators to do some positive work to the front end, opps some nice tyres made their way on there, hmm, maybe a quick stripdown and powdercoat for the frame.. And next year..

YOU ARE DOOMED!!!

Bore out the engine to 450, replace airbox with pods.....

Need a new zorst and headers now. Hmm, those Yosh headers should do the job, but the cans a bit dodge. Never mind, we'll swap it out for a Termi.....

Hmm, wouldn't a set of USD forks look nicer? Oh, look! These gsxr600 ones slot straight in.....

DOOOOMED!

kneescraper

14th July 2007, 18:51

Gezzz Jim, I thought the Katana was going to be a run about bike. By the time your finished it will be ready for a musiem. I wish I had time to do this to my RF400...mind you the Katana is more off a classic isnt it. Keep us up to date Jim.

James Deuce

19th July 2007, 19:07

Arrrrrrr!

<img src=http://yoshimura-shop.netmove.co.jp/product_image/gsx4s.jpg>

Ronin

19th July 2007, 19:27

mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm

Hitcher

19th July 2007, 20:04

Arrrrrrr, indeed!

Pussy

19th July 2007, 20:37

Arrrrrrr!

<img src=http://yoshimura-shop.netmove.co.jp/product_image/gsx4s.jpg>

You know you want to........

James Deuce

19th July 2007, 20:40

Probably HAVE to.

Storm

19th July 2007, 20:44

Definitly have to. We'll all lynch you if you dont.

(you do realise there are hordes living out their bike makeover dreams through you dont you:):):):) )

Pussy

26th July 2007, 20:36

Hey Jim, how about an update?

James Deuce

26th July 2007, 20:48

Fork legs have arrived. I have to ring F5Dave and get him to brutalise things in the vicinity of my steering head before I can continue.

Waiting for Yoshimura Japan to respond to my inquiry.

Thinks! Brian D'amarge!

Opening PM......

F5 Dave

27th July 2007, 09:31

Will be around sat but not sun. May even get into the garage later tonight.

James Deuce

30th July 2007, 08:35

Work kept me busy most of the day on Saturday and the youngest 2nd birthday kept me busy on Sunday, so I never got to take F5Dave up on his kind offer.

Picked up the fork dust seals, air filter, and fork legs (yay) on Saturday.

On Sunday I installed the air filter and put the seat lug/tank mount back on. Lubed the choke cable.

The air filter has a much bigger diameter velocity stack on it, so I sense some jetting changes in the near future, especially if I get that exhaust system I'm after as well.

Only a couple of weeks to go and K'erst will be back on the road!

James Deuce

30th July 2007, 09:22

I forgot to mention Richard from TSS. He's been bang on the money with the OEM parts I've ordered through him. No need to try again as he gets it right first time.

Very satisfying to order something, go home and bolt it on and have it right.

James Deuce

2nd August 2007, 23:18

The fork legs have been reassembled. Once again Richard from TSS has been right on the money and the dust seals and fork seals were perfect. The red fork oil that went in was significantly closer to fluid than the gray mud that came out.

Many thanks to nudemetalz for his expert guidance and jokes about buggering off and leaving me holding two fork legs with no fork caps on and full of oil.

Behold the shiny magnificence of reconditioned forks!

Right. Now for the steering head. I have to get the front subframe off so I can get in there with decent drift and bash those frigging bearing races out and I'm going to have to *gasp* probably take the stem down to someone with a press, or four burly lads with fingers like midget submarines.

riffer

3rd August 2007, 20:31

Do let me know when you do find someone who can do that Jim.

I need to do mine too, and I was considering using a bearing puller to get it off but I'm none too sure if it would work, let alone get the bearing back on all right.

James Deuce

5th August 2007, 19:54

Located some rear shocks through OK!shon (http://www.okshon.com/node)

A very kind KBer in Japan has offered to help with the procurement.

I'm getting black springs though.

Pussy

6th August 2007, 11:05

Hey, Jim, did you consider doing cartridge emulators while you've got everything stripped out? I can promise you it would make your forks VERY nice........

James Deuce

6th August 2007, 11:28

One is under the scrutiny of the "Financial Manager".

The fork reconditioning will be a significant improvement, I'm sure. Cartridge emulators can go in with the next fork oil change.

El Dopa

6th August 2007, 20:01

Located some rear shocks through OK!shon (http://www.okshon.com/node)

A very kind KBer in Japan has offered to help with the procurement.

I'm getting black springs though.

Is this person willing to help out other KBers browsing Ok!Shon?

I have my eye on some Keihin flatsides....

James Deuce

2nd September 2007, 20:55

Success!

In light of Paul in NZ's magnificent achievement, this isn't such a big deal.

However.

Upper steering head bearing race removed. New upper bearing ready to be inserted, once I acquire some grease.

The lower one is a different story.

Does anyone have a suitable idea for removing it? It is very difficult to get my, ahem, "drift" ('tis a large screwing stick) seated on top of the race so I can gently knock it out.

I really need a bent thing. With a curved thing.

Paul in NZ

2nd September 2007, 21:14

I have a lump of steel with a notch in it that I use for removing the universal joint carrier bearing in Moto Guzzi swing arms - it might do the job. I can bring it into work or I can drop over with a slection of blunt objects one weekend?

Paul in NZ

2nd September 2007, 21:15

Oh! Nother idea.. You could weld a bolt onto it and use a slide hammer?

F5 Dave

3rd September 2007, 10:03

You really need a mig so you can lay a bead on the race to shrink it so it falls out. I might have one you can borrow.

Paul in NZ

3rd September 2007, 10:22

You really need a mig so you can lay a bead on the race to shrink it so it falls out. I might have one you can borrow.

That would work.... :cool:

rogson

3rd September 2007, 10:23

Proper man-sized drift used with a man-sized whack does it piece of cake.
I picked-up a proper drift (has a hardened tip?) at my local second-hand tool shop for $10.

F5 Dave

3rd September 2007, 11:36

Proper man-sized drift used with a man-sized whack does it piece of cake.
I picked-up a proper drift (has a hardened tip?) at my local second-hand tool shop for $10.

Fabulous, bet he hadn't thought of that. Problem is often for some nefarious reason there is a lip on the frame that hides the lip of the bearing from a clear shot. My KDX for example I extracted the bearing with a mig & then ground two punch grooves in the lip for the next poor bugger who came along & noticed you couldn't see the bearing from the top let alone drift it.

James Deuce

23rd September 2007, 10:45

The lip inside the steering head was indeed the issue.

Thanks to et al and his modified steel bar, half a dozen gentle taps had the bottom race out in no time.

Work has been a bitch for the last month. No, hang on, I've been work's bitch for the last month.

Yesterday I cracked. Instead of turning up to work at 9am for yet more OT I installed the steering head bearings and reassembled the front end. Then after work I installed the front wheel and brake calipers and monkeyed up a mounting point for the old horn off the Z750 (Z750 horn has been replaced with a baby Stebel - the old Z750 horn is 50% larger than the stock Suzuki item) and set the tension on the steering head bearings.

No clunks and smooth throughout its travel. The old bearings were so knackered that the whole steering assembly used to rock back and forwards under braking.

The Katana is now a rolling chassis. I inserted the key and all the dash lights came on and the new horn tootled melodiously first pop. Nothing gets caught, the forks actually seem to hold the front end up instead of diving for the stops when you sit on the seat (or bare frame rails) and the brakes work without binding. It really is nice to see the bike resting on its medieval proctoscope of a side stand.

I've really appreciated nudemetalz' help. I wouldn't have attempted the whole front end rebuild without his gentle encouragement and now bloodied thumbs (sorry). Paul in NZ has provided more inspiration than he probably realises and F5Dave has no idea how comforting the thought, "If I stuff this up F5Dave is just round the corner", really was. Thanks also to Pussy for his rechroming contacts. I'm sorry that didn't work out because it would have been great to be able to pimp those guy's work on KB.

Richard from TSS has been superb. He likes old Japanese munt too, so rather than a derogatory scowl when I ask stupid questions he's helped figure out what I really want and then sorts it out, usually within 10 days. Front caliper piston kits are on the way.

Brian D'Marge. The toad won't answer emails requesting a bank account number so I can pay for the shocks he helped me find on OKSHon. One day Brian D'Marge, one day.....

Crazefox and MSTRS have provided paint and decals respectively, and both of them are superb to deal with, full of great ideas. Comments like, "I've put 2 sizes of decals and a couple of Katana decals (kanji symbol) in the package as well", from MSTRS and "I can still feel the edge of the decals through the clear coat, so I'd like to give it a couple more coats", show just what sort of people inhabit KB.

I'll post some pictures up tonight. If I ever get home from work.

I'll be picking up crazefox's handiwork in the next week or so. He and his partner have just had a baby girl, Elley (sp), so he's a bit preoccupied. Don't forget to congratulate him people! Once the bodywork is installed I'll post some more pictures. Then it's off to get the mufflers repaired and some new headers priced up. Until then the howl of a small capacity multi will be plaguing Wellington commuters. Sounds just like a 4 cylinder 350cc MV that Ago used to ride.

merv

23rd September 2007, 11:07

Going well Jim, glad to hear you finally got the bearing out.

James Deuce

23rd September 2007, 19:49

Pictures as promised.

Bit funny really. You can't see where the real work has gone in. Trust me when I say the old stanchions were horribly pitted, the fork oil was indescribably disgusting and the rotten air filter was a sight to behold. Look at the size of the bell mouth on the new air filter compared to the old one, further back through the posts.

All those rusty bits you can see will be coming off to be painted by crazefox, sometime before Christmas. The pistons and seals in the brake calipers will be replaced in the next couple of weeks along with the rear shocks. Xerxesdaphat, if you're looking at this, those brakes are good example of why cable operated drums have been rightly relegated to Museums and well loved and maintained classics. I can't say I was particularly enarmoured of the cable operated front drum on my CSR250. You were never sure you would have any brakes at all.

I've cleaned up the chassis components a lot and I've gone to town with lubricants to free up bolts.

Under that steering head are some of SKF's finest work with tapered roller bearings and a lot of strange looks from the guys at Schrodoco. Also, blood, skin, 30-40,000 expletives about engineers who leave an exposed edge so you can get a bearing race out but then put a lip over it, and about 100gms of fresh grease.

The horn really is better than the old one. I've yet to look at the alternator output to see if I can put the grown-up Stebel on.

Honestly, all those rusty bits will be sorted, I promise.

Paul in NZ

23rd September 2007, 21:26

Good onya Jim... It sure takes your mind OFF work and yet motivates you to go back ($$) eh?

Pussy

23rd September 2007, 21:55

Buy the yoshi system, buy the yoshi system, buy the yoshi system........

James Deuce

24th September 2007, 05:59

I'd buy it if they answered, I'd buy it if they answered, I'd buy it if they answered.....

Busy

24th September 2007, 09:18

I stumbled upon this the other day

Brian d marge

24th September 2007, 15:48

Brian D'Marge. The toad won't answer emails requesting a bank account number so I can pay for the shocks he helped me find on OKSHon. One day Brian D'Marge, one day.....

Not until they arrive and you are happy with them and I see a photo of your happy smiling face holding a freshly caught fish above you head ,

Stephen

James Deuce

24th September 2007, 15:51

Gaaah! Fish!

Alright, deal :)

crazefox

24th September 2007, 17:23

Mate im home now so come over whenever

James Deuce

26th September 2007, 20:56

I went and picked up the painted bits this evening.

I feel like I ripped crazefox off! You can't look at the tank for too long before vertigo makes you slowly but surely fall into the tank.

All the other bits, from the guard to the nose cone to the little doohickeys under the tank look way better than when I bought the bike, better than new even!

My tribute to a mutual friend of Paul in NZ's and mine is nice and subtle and just a little off centre - precisely how Ken would have liked it!

K'erst was his nickname and the spelling came from a language he invented, one wot was loosely (Vicar!) based on Engurlush. He often sneered at modern bikes as foppish affectation, so I'm sure he'd appreciate his appellation (you kids get out of my orchard!) adorning the front of a partly perfect, partly decrepit, thoroughly archaic tribute to boiks of twenty foive year ago.

Sorry about the horrid photo and poor light. Should give yer an oidea of wot it is loik but.

Pussy

26th September 2007, 21:05

Hey Jim, I've got a side cover of a 650 Katana lying around somewhere, not sure if it's left or right.... new but needs painting. Would it fit the four hundy?

James Deuce

26th September 2007, 21:06

Nope, but thanks for the offer!

James Deuce

27th September 2007, 00:24

Here we go!

Once the rust sealer on the bottom of the tanks sets, we are good to rock and roll.

At least until the headers explode and I get pink stickered for those "mufflers". Yes, "mufflers, that's what they are.

Isn't it nice to work in the gargre?

Check out MSTRS' superb work on those decals and crazefox's lustrous paint work(ignore the brown tinge - that's a testament to the 3cm deep clearcoat and some weird reflections caused by the flash)! I can't recommend both of them highly enough.

Shocks to go. Then the next paint job is all the little frames and brackets.

I only had one screw left over and I know exactly where it should go.

arsnik

27th September 2007, 01:04

I only had one screw left over and I know exactly where it should go.

[/LEFT]

WEll done. I have bucket loadds of \"spare parts\" from many a complete bike

sAsLEX

27th September 2007, 03:53

I only had one screw left over and I know exactly where it should go.

And no spare holes?

So where is the arse of it?

James Deuce

27th September 2007, 07:07

I have a spare hole (eek) even!

The arse is all there. It's quite amazing how the seat completes the bike.

Hitcher

27th September 2007, 08:57

It's quite amazing how the seat completes the bike.

Wasn't that a line from Jerry McGuire?

F5 Dave

27th September 2007, 09:25

Good when a bike starts to come together & the anticipation of riding it is escalating.

Paul in NZ

27th September 2007, 10:06

Thats looking NICE mate....

You going to do the headers?

James Deuce

27th September 2007, 10:13

I'm not sure I understand the terms of reference for "do".

Replace? I planning to. In fact crazefox said to me only last night, "I know a guy..."

It's all about contacts.

I finished reassembly this morning.

It looks marvelous.

A nice new front tyre in the correct size, will be going on Saturday morning.

Hopefully the lads can see if they can weld up the exhausts too.

Paul in NZ

27th September 2007, 10:23

Sorry - they looked a bit brown in the picture.... From memory they were a black chrome finish similar to moto guzzi ones which was not quite as durable as one would expect and I assumed yours had corroded as well.

I searched a fair while before i found a cheap way of replicating the finish but it was not fabulous and needed repainting annually. HPC coating is the answer of course but it's not cheap. The best alternate I found was a base coat of VHT matt flame proof paint with a coat of their clear satin over the top. It can be cleaned by using a cast iron stove polish - messy but a bottle lasts yonks.

James Deuce

27th September 2007, 11:11

I may need your help with that one Kemo Sabe. It sounds like an excellent plan and we should do Lunch to procure the correct elements and communicate the process to that Jim fella. I should do that as a short term fix, but I want to get some stainless headers made up as I'll be riding the bike in the rain (gasp).

I forgot to mention. I broke one of the plastic locating pins off on the right hand side panel. Plastic welding here we come! I have a kit from when I fixed up the CBR600. I think I was too excited.

F5 Dave

27th September 2007, 11:51

That's a drag those pins, esp after paint. What I like to do is run a countersunk bolt through from the outside & either make it look like it should be there or sticker over it, ideally fill & paint over it, but the bolt can then thread into a carefully drilled hole in the pin & glued.

crazefox

27th September 2007, 13:58

James Deuce

27th September 2007, 14:07

Done - alright tonight?

James Deuce

28th September 2007, 00:38

The plan was to finish assembly and hoon around to crazefox's place to sort the broken pin.

However I had the usual post assembly dramas, the major one being leaking carb O-Rings. CRC and a screw driver had that sorted, but I'd had to rip the tank off in the process, so I canned the trip to crazefox's and re-booked for later.

The moment of truth involved trying to decipher the fuel tap (I STILL have no idea what it's point at really) to prime the carbs, then juggling three hands to adjust choke, throttle and hold the starter button down. 30 seconds later and that raucous guttural roar is back! Yeah Baby!

This is where I made my first mistake. I turned it off instead of going for a ride. There was a bit of clicking next time I thumbed the starter and then it all went dim.

Out with the charger, inside for an hour of nervous fidgeting and then back out to the gargre - brrr, brrr, brrrr ,putt, putt, brrr, putt, blup, bluppppppp, bwaahhhhh, blippityblipptiy. On with the gear and off down the road.

I got 100 metres down the road and then realised that the front suspension and steering had been assembled by me. Save me Jebus!

This frozen panic only lasted as long as the next approaching vehicle however, and once I'd unbitten my tongue I couldn't believe the difference in steering and suspension manners. The first mission was gas and air for the tyres.

Prepay Gas Station. Luckily Eric at BP Melling took pity on me, hung onto my eftpos card and let me just fill up and then pay for it. I reckon that could be a goer at most prepay stations if you asked nicely.

Air. The suspension had felt bouncy to say the least, a series of bumps creating a standing wave from headstock to taillight, causing an alarming porpoising effect. The front tyre was at Rantydave levels of atmospheric depletion. 16 PSI. The rear was better at 22. 36 front and 42 rear fixed that. Phwoaar. Old school stability and suspension that soaks up the normal bumps of the average road.

Speaking of tyres the Conti TKV 11 on the front of K'erst is an example of why ignoring the manufacturer's recommendation about sizing is a gamble at best. I gently pootled around the hills. I'm right to the edge of the front tyre which is both too tall and spread flat. There's 2.5cm chicken strip on the rear Sport Demon. The proper tyre fitment is a 100/80x18. On it is a 110/80x18. The BT45 is going on to the front wheel on Saturday. Until then I have to control my angle of dangle instinct. It isn't easy!

Thank you for putting up with this extended remix of bike resurrection.

So far the team of experts and I (the token non-expert) have painted the bodywork and redone the decals, rebuilt the headstock internals, replaced the air filter, and replaced the fork stanchions and redone the fork seals including dust seals. I've had to free up rust welded drain screws in carbs, buy an impact driver to shift rusted bolts, and generally try to undo someone else's lack of TLC.

All up I'm just a smidgen under my $3000 budget, but I'm about to go over this by about $300 when I rebuild the front brakes. Way short of the normal estimate of what you THINK you need to spend, double it, and then double it again, and that budget management is entirely down to nudemetalz, crazefox, MSTRS, and TSS. Lets not forget Schrodoco, even though they think I'm a PITA.

As I said at the beginning, this bike is meant to be my daily transport and as such it will be a rolling restoration. The exhaust system needs urgent attention and I think I'm just going to have to bite the bullet and head for Cycleworks.

I still can't believe it works! I even beat a car that goes pssh away from the lights and delivered him into the loving attention of Mr Plod whom I'd spotted just up the road. Not bad for an old fella.

merv

28th September 2007, 08:07

Yep Jim excellent work so far. Not bad for a "token non-expert".

MSTRS

28th September 2007, 09:08

Very well done, young fella. Have been thoroughly enjoying the read on progress too.

nudemetalz

28th September 2007, 12:06

Great stuff Jim. She's a wee beauty that 400 Kat. People here would love it just as their own bike, let alone just a "commuter" :2thumbsup

et al

28th September 2007, 12:25

Nice Jim - looks better than a bought one. Just thinking maybe it needs a bit of red somewhere - since you seem to like red things at the moment, you should see the shoes he is wearing today folks!

White trash

28th September 2007, 12:30

Lookin fantastic old boy. You're right about the exhausts too. Purely from an aesthetic standpoint, once those headers are cleaned up (thrown out) it's going to be one wicked cool looking machine. Well done.

Between yourself and Paul you're doing a great job of resurecting the proper KB show and tell on how things get done. I like it. Me and Sue have got a little project on the way too.........

MSTRS

28th September 2007, 13:09

.... Me and Sue have got a little project on the way too.........

Yes yes, we're sure you have....but this is a family show:wacko:

Paul in NZ

28th September 2007, 13:11

Me and Sue have got a little project on the way too.........

What? Did you get Sue preggers???

It's looking great Jim... Its a bit of fun getting these faded warhorses back to health. In 10 years time we will be kicking ourselves for not scooping up more of em....

Paul in NZ

28th September 2007, 13:12

Nice Jim - looks better than a bought one. Just thinking maybe it needs a bit of red somewhere - since you seem to like red things at the moment, you should see the shoes he is wearing today folks!

Oh gawd - old Katana - red shoes, works in IT - hes gone native...

Swoop

28th September 2007, 14:47

Damn good stuff Jim!

Have been enjoying the read immensely. More piccies would compliment the thread though.

Getting close to the stage of having to take her out to a scenic spot and take some piccies without a garage background!

:niceone:

James Deuce

28th September 2007, 14:48

Flamin' 'Eck!

Lookit this!!

I could not be a happier bunny. nudemetalz will be growly but at this price he can just sit in the corner and be quiet!

$250.

Sorry about the long pause there I fell off my chair again.

I did a search on Trademe for "Katana" in the exhaust section and it comes back with Full System for Retro 400 Katana.

I'm gobsmacked. I nearly smiled.

Cajun

28th September 2007, 14:59

nice score Jim
will look awsome on there

nudemetalz

28th September 2007, 15:29

Ha ha "I'll be growly ??". :girlfight:

Still think the Kat 250 4:1's the way to go for styling but hey, it's a full Yoshi system. I guess a new price would be "think of a high price and triple it!!"

Hitcher

28th September 2007, 16:08

I did a search on Trademe for "Katana" in the exhaust system and it comes back with Full System for Retro 400 Katana.

One wonders as to the fate of the rest of that particular Katana...

James Deuce

28th September 2007, 16:20

Yes - the radiator looks particularly good. I wonder how good the screen is?

James Deuce

28th September 2007, 19:25

You know you want to........
Heehee I did!

Pussy

28th September 2007, 22:38

Heehee I did!
Great score there Jim, it will just finish it off nicely, after the cartridge emulators are in......

James Deuce

29th September 2007, 11:26

Woohoo! BT45 Front fitted. Seriously improved directional control and way more stable when tipped over. No longer feels like I'm falling off the edge of the front tyre. Blimey this thing is stable. Didn't people in the 80s want to go around corners?

Other breaking news: I've nearly fixed the hernia I created by trying to lift the back end of the Kat around. I can life the back end of the Z750 no worries. Don't leave home without a truss.

yungatart

29th September 2007, 11:30

Other breaking news: I've nearly fixed the hernia I created by trying to lift the back end of the Kat around. I can life the back end of the Z750 no worries. Don't leave home without a truss.
[/LEFT]

Ummm, so pleased to hear that bit of news!
We really can't have you spilling your guts in public...it's not a good look!

MSTRS

29th September 2007, 11:56

Ummm, so pleased to hear that bit of news!
We really can't have you spilling your guts in public...it's not a good look!

Not a problem...we like to keep up with all the gossip.
It's 'dropping your guts' that we object to....

nudemetalz

29th September 2007, 20:07

Woohoo! BT45 Front fitted. Seriously improved directional control and way more stable when tipped over. No longer feels like I'm falling off the edge of the front tyre. Blimey this thing is stable. Didn't people in the 80s want to go around corners?

You gotta remember, back in the 80's, tyre technology wasn't as good (who remembers Bridgestone Mag Mopus) so they slid around the corners !!!

James Deuce

29th September 2007, 20:47

crazefox fixed the pin. He's legendary with toxic chemicals.

Just an exhaust system, carb balance and clean, and an oil change to go.

Paul in NZ

29th September 2007, 21:32

crazefox fixed the pin. He's legendary with toxic chemicals.

Just an exhaust system, carb balance and clean, and an oil change to go.

Carb balance? You wanna do it here or your place?

James Deuce

29th September 2007, 21:34

Your place sounds ideal :) Thanks for the offer. See you after the new exhaust system is installed.

James Deuce

1st October 2007, 09:26

Left over screw installed. Fairing buzz banished.

Want my new exhaust system, want my new exhaust system, want my new exhaust system, want my new exhaust system...............

nudemetalz

1st October 2007, 11:39

Want my new exhaust system, want my new exhaust system, want my new exhaust system, want my new exhaust system...............

Just what are you trying to say.....??

MSTRS

1st October 2007, 15:41

Just what are you trying to say.....??

He's going in for surgery on his piles?

James Deuce

4th October 2007, 18:37

The shocks arrived from Japan today.

As this project has progressed, one thing I've learned about motorcycle restoration is never procrastinate. As the bits turn up, assemble, paint, lube, install, do whatever is required to make those parts usable right now. If you aren't performing a piece of work, make sure the expert you've thought about entrusting the job to, actually has those bits and has them in their work queue. Just so long as they aren't sitting on your shelf mocking your inability to actually ever finish ANYTHING.

So I installed them myself. Grease is your friend. A car jack and a piece of wood can do the work of three men. Never let your wife see you holding the bike up with one hand (on the jack) with a shock removed trying to get that nut that just rolled *over there*. Somewhere. Keep a rubber mallet to hand.

Never.

Give.

Up.

The shocks are stunning to look at, with gold anodising and a dual spring arrangement I've never seen before. They are adjustable for ride height and preload, and they most definitely hold the arse of the bike up off the floor. The bike is a good 10mm higher at the rear at rest, despite the shocks being exactly the same length as the Showas I took off.

I thought about going for a quick shakedown ride, but quickly flagged it as the wind here is both high velocity and unpredictable at the moment. We all know that new parts increase the attraction between bike and ground almost exponentially for the first couple of hours, so I've parked K'erst and run upstairs.

Parts of me I didn't know I had are hurting, but it is very worthwhile. Here's some fairly horrible pictures to look at. Terrible light, gale force winds, and a human vibrating with exhaustion have conspired to overwhelm my camera's anti-shake function.

Exhaust system, spark plugs, oil change and carb clean/balance to go.

Rock on.

nudemetalz

4th October 2007, 20:38

They look nice.

merv

4th October 2007, 21:05

The shocks are stunning to look at, with gold anodising and a dual spring arrangement I've never seen before.

Looking good and mate are you meaning the dual spring arrangement you hadn't seen before or just in combo with the gold anodising because way back in 1973 my XL175 had dual springs? Short soft springs for the small bumps and the longer harder springs for big bumps.

Except back then they hadn't really figured out about unsprung weight so they were mounted up the other way with the heavier shock body end attached to the swingarm.

crazefox

4th October 2007, 22:39

F##K yeah jim im sitting here drinking your beer looking at that bike mate.SHE is looking great man.Good shit man have too come for a ride with ya

F5 Dave

5th October 2007, 08:18

That does actually look real good Jim.

S&W Street Strokers had the dual spring setup & were the Boowai shock in the eighties if you had an XR250 or somesuch.

or maybe they made road & dirt versions. . whatever, too long ago.

Pussy

5th October 2007, 11:15

James Deuce

6th October 2007, 13:02

New plugs. Idle problem fixed. I will report on whether or not the top-end miss has been fixed as well. I made sure I connected the fuel tap breather hose properly this time.

The old plugs look like they'd been gapped using a $5 whore as a template.

James Deuce

6th October 2007, 14:39

Running to redline on partial throttle quite happily now and much better low-end and mid-range power thanks to the new plugs. Not running cleanly at full throttle past 9000rpm however, so I suspect that the carbs will need to be pulled and cleaned.

Steering head is clonking, though I suspect that just means it's all bedded in now and I need to adjust the bearings.

Bugger.

Edit: Maybe not "bugger". Problem clearing with use. Definitely needs a carb balance at least.

F5 Dave

8th October 2007, 08:44

I was going to suggest you pop around the corner & show us the new bike, but the wind has been horrendous. Hardly slept for last couple of nights.

Bullitt

8th October 2007, 17:34

Saw it on the way home from work today.

Looks good:clap:

James Deuce

8th October 2007, 17:48

Thanks Bullitt.

Thanks to nudemetalz the steering head has been re-tensioned.

The new exhaust system is going on this evening. The old one was a piece of cake to take off. Should I use copper grease on the collet bolts?

Pictures soon!

James Deuce

8th October 2007, 20:05

The Exhaust system is on!

It has about half the decibels of the old rotted system and about half the weight.

Once I cleaned it up it looked very special indeed. I got all the yellowing off and all the tar, and all the blue to discover a lovely Yoshi stainless steel header system under all the gunk.

The cast aluminium can is a bit pitted and stained, but a few weekends of attacking it with Mother's alloy polish will bring it up nicely.

Installing it was like the "Requires three hands!" Meccano kit from hell. Managed to get my tongue to do things it never, ever should and once the can was bolted up I started K'erst up.

I stood back as I was expecting the hellish row that emanates from open exhaust ports. I got the utter opposite. Let it run for a bit and listened for any ticking sounds from the headers. Only one of them started after about 10 minutes. Gave the collet bolts a little tweak until the ticking went away.

I then went and placed my hand in a bucket of cold water.

Once the screaming had stopped (it could have been me) and I could hear the exhaust noise again I shut K'erst down and went in for a cuppa. Once again I fought down the urge to ride anywhere, fully aware that my "new parts:gravity magnification" ratio had shot up to maximum gain.

Pictures in the morning. I can't get good shots with the illumination as it is at present. The glare from the headers makes the rest of the picture look blurry.

Right then.

Caliper pistons and seals to be replaced, an oil and filter change, and a carb clean.

The list is reducing in length.

nudemetalz

8th October 2007, 22:40

Well done, Jim.
Looking forward to seeing what K'erst looks like with the Yoshi part.
Also interested to find out how the engine now carburets too.

xwhatsit

8th October 2007, 23:10

Let it run for a bit and listened for any ticking sounds from the headers. Only one of them started after about 10 minutes. Gave the collet bolts a little tweak until the ticking went away.

What does this mean? My silly twin megaphones `tick'.

I had to tighten up my steering head bearings when I did them too, they seemed to bed in and get slacker.

Congrats, by the way. I like it. Next bike will be a 400-550cc straight four. CB400 Four if I win Lotto, else CB550 Supersport.

`Balance'.

James Deuce

9th October 2007, 05:18

If it is ticking right up by the head then the exhaust is leaking right at the manifold/port juncture. Some people get all upset and replace their camchain tensioner when they hear this noise.

James Deuce

9th October 2007, 06:30

Amazing what $1.25 worth of Scotchbrite pad can do.

Pwalo

9th October 2007, 06:48

That's looking really good. I reckon the 400 is the best balanced looking of the older styled Katanas.

Just a touch up on the engine paint, and it'll be looking pretty mint.

Swoop

9th October 2007, 07:11

Ohhhhhhh, Yesssss!
Veeery nice.

Lookin' good.

yungatart

9th October 2007, 07:19

Ohhhhhhh, Yesssss!
Veeery nice.

Lookin' good.

What he said!

Can I take it for a spin?....please?

MSTRS

9th October 2007, 07:43

I foresee an article in Kiwirider. You've done yourself proud, young James.

Hitcher

9th October 2007, 07:48

Those replacement headers have probably transformed the look of the K'erst more than any of the other modifications. The bike now looks "finished" and very authentic. Nice work.

Swoop

9th October 2007, 08:10

I foresee an article in Kiwirider.
That is a very good idea!

Macktheknife

9th October 2007, 08:27

Bloody nice work there Jim, what a beauty!

nudemetalz

9th October 2007, 10:05

Beautiful !!!!!!!!!!!!!

Yoshimura pipe on a Katana....go back 25 years and you'd hear of the same !!

James Deuce

10th October 2007, 05:37

What he said!

Can I take it for a spin?....please?

Yes of course, so long as I get a go on the GPz! :)

James Deuce

10th October 2007, 05:38

I foresee an article in Kiwirider. You've done yourself proud, young James.

Alright then, I'll give it a go.

yungatart

10th October 2007, 07:13

Yes of course, so long as I get a go on the GPz! :)

Done!!
Woohoo!
When?

Hitcher

10th October 2007, 08:53

It purrs. Beautifully.

James Deuce

13th October 2007, 15:07

Oil change, Carb Clean and Rejetting all done.

My word what a difference. Mike at TSS can be justifiably proud of what he's done, as it was running like sprinter with a collapsed lung. Too much throttle and it would bog.

I rode over the Paekakariki Hill this morning and then made Paul in NZ come for a ride on the FZR. (After watching him mow the lawn and do his edges - I love watching competent people do good work) I also wanted to try out the new RJAY's tailpack I bought. It has a bra arrangement (just like the All Blacks - all support, no cup) that you can clip the bag to. Means I won't ruin the wonderful crazefox paint job with a tank bag and I won't ruin the classic Katana lines with a pack rack.

The Kat just sings now, and the tacho will go well into the red without feeling like it's getting breathless. The soundtrack is vastly improved without ever getting too loud, the handling is wonderful on smooth roads. Too many bumps and the feedback starts to get a bit urgent.

We swapped bikes at the Pauhatanui Challenge petrol station. Same class of motorcycle, similar era, but hugely different to ride. The FZR's chassis stiffness is immediately apparent as is the late 80's requirement for a bit of muscle to get it to turn. The engine on the FZR feels much stronger than the Kat's but that may be because the engines are tuned for totally different purposes. The Kat is strong down low and in the mid-range compared to the FZR and doesn't have any real steps in the power delivery. It just gets stronger and stronger, where the FZR definitely "comes on the cam" and races away.

Us old blokes on 400s are having fun kids, and both bikes show what can be done with a little money and a lot of effort. Everything I do from now on will be little cosmetic enhancements. Intervention complete. Time to ride and maintain.

nudemetalz

13th October 2007, 15:41

Good to hear that she's finally going well.

You're making me consider that I should buy a 400 now.
However after the last experience with the RF400, I don't think Mrs will let me :no: .

Paul in NZ

13th October 2007, 19:01

My life at work is a pile of shit at the moment and to say I'm stressed is a bit of an understatement - real looking at the ceiling at 3am going crap crap crap stuff - I need my sleep!!! So this morning some git arrives at the front door so early he obviously crapped in his own bed and was certainly going to deneigh me an appointment with morphus or a sat morn shag... Oh well - I had to get up anyway - bladder was full.... I think Vicki liked the Kat or she has a thing for Jim2 'cos she was calling out Jims here, jims here like some kind of cheap car alarm but it had the desired effect and I had a shower and shambled out to look at the beast... fark - very nice mate...

Jim2 obviously thought I needed a ride but I thought I'll make the beggar wait while I mow the lawns - with all he rain they ar growing fast! Then here was a search foe vickis phone - we gave up after looking under Jim2 times and later it turned up inside Vickis glasses case - no - I have no idea either - just go with it...

Finally time to go for a teeter...

The FZR just gets better and better. Jim2's Kat is a completely different bike to ride to the FZR except for one thing - it's still fun! I cannot believe how well these 400's go... Fabulous! Jims done a GREAT job on that bike, it idles, runs and sounds wonderful. Its midrange is just creamy, what a wonderful bike and waaaay better than the fizzer as a commuter / general purpose bike. I reckon the FZR is a better sports bike as it is just soooo frentic / nuts / rev hungry but that can get tiring - the Kat has a more comodious riding position etc. It would be a way better bike to ride to auckland and it has a useful pillion seat.

I left Jim2 after we visited TSS and I looked at Jim2 trying on stuff in an effort to look as cool as his bike. I whizzed home over the hill letting the wee fizzer have its head and being even MORE amazed at its manic personality... Hilarious....

ANYWAY! These bikes are a testament to average blokes in sheds bending metal and having fun. Its also an up yours to 'thou must only buy new and only take your bike to a posh shop' type mentality... In the age of the internet, cheap tools and on line manuals - small miracles can be achieved - well done Jim2 and welcome to blokedom....

Shiny side up

29th October 2007, 17:58

I used top have heaps of fun on an old 650 Kat. Shaft drive model. It got seriously binned by a golden lab dog. (they don't really fit between the the front wheel and the pipes, tends to bend the clamps) Any how I think I still have the manual around here somewhere (haynes) is it of any interest to you?

James Deuce

19th November 2007, 16:55

Cheers for the Offer Shiny, but I don't think the 650 is that related to the 400.

James Deuce

19th November 2007, 16:56

With all the stuff that's been going on I forgot to report something very pleasing.

The Katana sailed through its first WoF on Saturday. That's first WoF since being dealt to by me and Nudemetalz.

Just like that.

I don't know why I was so nervous.

Bonez

19th November 2007, 17:03

James Deuce

19th November 2007, 17:11

Luck!

And thank you.

Hitcher

19th November 2007, 20:03

"Hop on and go for a spin before you take your gear off," says Jim2.

Not often needing to be invited to do things a second time, onto the Katana I hop. Pegs, levers, controls, dials, lights all in the usual places. I click it into first and tootle down Chez Jim2's driveway and out onto the main road.

"Golly this thing is tiny."

Up through the gears and off down one of the Hutt's better biking roads we go. The gearbox feels very Suzuki and complements nicely a very willing and smooth-as-silk 400.

Corners arrive, and the Katana seems to have them well memorised, wanting to turn in about a quarter of a second or so before I was quite ready -- guess who had just spent the past 450km that day riding an FJR1300 with a shagged front tyre...

Into the lay-by at the bottom of the hill and time to retrace my tracks -- on the other side of the road this time, of course!

Also time for a bit of curry and to hurry this wee beastie along a bit, now that I am becoming accustomed to its lack of bulk, lovely precise handling and pearler of an engine. Going up hill leads to close encounters with personnel access hatch covers right on one's line, and a bit of improvisation is required. The wee (and I use this word in a relative sense) Katana is completely unfazed and soon enough we're back in front of Jim2's garage looking for the side stand which appears, for all intents and purposes, to have escaped from Dr Findlay's little brown bag.

Jim2's first foray into the world of project bikes is a huge success. Suzuki-san never expected a Katana 400 to be this good.

James Deuce

22nd March 2008, 10:16

yungatart

22nd March 2008, 10:25

I will beat the new owner severely if he does not look after the Kat!:spanking::spanking:
It has had far too much put it in to it to see it go backwards...
Can't wait to see it parked in my gargre and I know that John is looking forward to riding it home this avo.
I'll even go so far as to give it a spit and polish before it heads off to its new owner...
Good luck with the new purchase, Jim.

xwhatsit

22nd March 2008, 12:14

The hell?

Well I approve of the dual-purpose bit at least. Still, should've sold the 750 ;)

MSTRS

22nd March 2008, 18:10

All tucked up in the gargre now. Great little bike for a pootle on....:2thumbsup

McDuck

9th September 2008, 17:31

Well, k'erst is off to life in the Bay, with a new owner to be announced in the next few weeks.
Parting is such sweet sorrow.

Time to start saving for that dual-purpose bike.

It got a send off clean and polish yesterday and a final set of photos.

The bottom photos give an idea of far gone k'erst was. The ones on the top and right show what can be done for less the the price of a set of tyres, a major service, and decent night out.

<img src=http://www.kiwibiker.co.nz/photopost/data/529/medium/Bye_Katana.jpg> (http://www.kiwibiker.co.nz/photopost/data/529/Bye_Katana.jpg)

The Katana went from daggy and dangerous to reliable transport and I've done the better part of 6000kms, from 13,300kms to the near 19,000kms shown on the speedo now, from commuting to charging about the hills and valleys of the Wairarapa.

It had a power curve that emulated those peaks and valleys, but now it is one of the smoothest bikes I've ever owned.

Good luck and good fortune k'erst. Time to bring pleasure to someone else.

Dont worry, i have almost washed it since i got it. I have also done two 1000km + round trips on it and i love it.

As a testement to its good-ness he was outside (no choice here, trust me) for nearly 2 weeks (busy with tech etc) not even looked at starting. Anyway one morning i looked at him and decided to start it to give it a warm up befor heading off to work. I was expecting to have to work hard to start it with choke and gas. NOPE. started strait up with no throttel or choke needed and slipped into a nice smooth idel. even tho the top of the seat was frozen it was fine. :)

i love it :love: