Katana 400 intervention begins

**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

**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

Originally Posted by Jim2

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

Originally Posted by Swoop

Ohhhhhhh, Yesssss!
Veeery nice.

Lookin' good.

What he said!

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

**MSTRS:Me** · 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.