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Project Popup

I've acquired a 1985 GSX750SE3 Katana Popup for the princely sum of $1.

I'm going to try and do it up the old fashioned way - without opening up the wallet as much as I can.

Restoring this bike is going to be done through hard work in the gargre with as much work as possible done by me.

  1. Cleaned up the exhaust

    I've attacked the exhaust with a steel brush, and it's come up pretty good.

    Next step will be to use a wire wheel and give it a really good clean, then sand it back to a paint finish, then it'll get a nice UHT matt black paint on it.

    It looks to me like a 1990s vintage Cycleworks 4 into 1 in damn good nick.

    I've got some new packing stuff for the 'zorst and as soon as I can work out how to get the slip cover off I'll repack it.
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  2. A new front end for the Katana

    Okay, so its Saturday and I've got some spare time this weekend. Not raining yet so let's get out to the gargre early and drag out the bike.

    Those front fork stanchions are looking very sorry, and I've picked up some replacement forks at Buckets and Bits which will do the job nicely.

    Looks to be a piece of cake to get this front wheel off. It's a little bit different to the RF, but easy enough to work out. Previous owner has done up the axle WAY too tight though so I decided ...
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  3. Possible brake upgrade

    So, I've been talking to Pete at work and he's got some spare calipers from an RG500 that will fit to my forks.

    With the twin pots it should provide much better braking.

    I'm also looking at getting an RGV250 master cylinder off him as well to complete the setup.

    Now combine that with braided lines and I should have some pretty sweet brakes on this thing...

    Of course it's not going to be cheap. I'm starting to realise there's no such thing as a ...
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  4. I have actually been doing some stuff on the bike...

    Yeah, I know. Haven't posted in a while.

    So, what's happened with the bike? Well, so far I've done this:


    1. Completely dismantled the rear caliper and rebuilt it.
    2. De-rusted, sanded, primered and painted the rear caliper torsion bar and front fairing bracket
    3. Used a steel wire brush to remove all of the rust from the exhaust headers.
    4. Removed the rivets from the exhaust muffler shroud, and removed the shroud in preparation for the repacking of the muffler.
    5. Completely
    ...