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Zombie 600 Kat being more of a corpse

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  • #1

    Zombie 600 Kat being more of a corpse

    Sooo as in my 're introduction' (heheh) i traded for a 600 Kat, beat all to hell and a post track bike at that (explains the two fist sized dents in tank).

    I got it cheap because the no.1 sparkplug was stripped. So i put the nasty plastic damage aside, the dents, the race tires and the extended and lowered'ness of it and said.. 'this is a proj bike for me'.

    Now, heres to date the issues.

    Purchased heli coil to repair plug hole ($75)... fixed that no prob. Head was a pain to pull off. Ordered new headgasket ($56).
    While waiting on gasket i worked on the rather disgusting build up of carbon and what not on the valve side of head. (cams and such looked great)...the piston tops looked bout as rough.. cleaned them too.

    After gasket came in, started the rebuild. After getting head back on and bolted down, dropped a cam cap bolt and it fell thru the oil tube. Oy head BACK off, and retrieved bolt. Incidentally found a head nut washer (copper) sitting on the crank gear. Head BACK on again...torqued... and was on the cam cap bolt and SNAP.

    This is where i say to any newbs.... TAKE YOUR BLESSED TIME AND PAY ATTENTION. I completely forgot to reset the torque wrench.
    So now i have a head with a snapped cam bolt. I got an ezout and damned if that wouldn't work. I dunno what those bolt are made of.. but not even a cobolt will drill thru it. It seems like the bolt has smoothed out and the bit wont bite. So i've ordered (ebay) another head (with cams $112) and will be getting that this friday.

    I just wanted to vent, mainly at my own stupidity, as a warning to others working on the kat motors.... take your time....easy does it.

    At least in this 'wait' period, im working on the plastics painting.

    Feel free to make fun of me. My buddies already have.. LOL.
    "The two most powerful warriors are patience and time!" - Tolstoy
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  • #2
    No need to poke fun... Sounds like you are having a tough go but still trying to resurrect what may tunr out to be a fun bike at the end... Good luck with the rebuild and post some pics when you get a chance.. we like pics....
    "Life is what happens when you make plans..."

    http://katriders.com/vb/showthread.php?t=119546

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    • #3
      OMG and the hits just keep on coming.
      in prep for new head, i pulled old one and in doing so one of those stupid
      copper crush washers dropped down to the timing gear. yay. I did this once before and just fished it out. Well THIS time it slipped and fell down to the left of the gear towards the front outta site.

      My question now is... can i pull the oil pan and find that lil bugger ??
      I've looked at the fisches and cant tell if its in the bottom of the crank case or if its went to the oil pan or some limbo in between?

      Ughhhhh.
      "The two most powerful warriors are patience and time!" - Tolstoy

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      • #4
        Meanwhile, whilest still waiting on parts and such. I been tryin to strip the tank of its 'custom' paint and decal job.

        Lemme just say...what happened to doing things right?
        There must be at LEAST 5 layers of different paint on this tank?!!!!

        I've used almost a gallon of stripper to 'soften' up this tank...and keep finding new layers. LMAO.

        I have about 30-40% metal showing thru and just am amazed.

        When i did my vulcan, it was factory and took like three applications to strip bare.
        "The two most powerful warriors are patience and time!" - Tolstoy

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        • #5
          If bringing bikes back to life was easy, everyone would do it. All this Pain in the A$$ stuff now makes it that much sweeter wher you're back on the road.

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          • #6
            LOL i keep tellin myself that over and over. Its not hard to do at all... compared to my vulcan which is a bear to work on. I shudder to think about touching that motor. The kats are just sooooo easy.

            Guess i'll go searching for that washer, then work on the paint some more.
            Gotta upload some pic's ive taken.
            "The two most powerful warriors are patience and time!" - Tolstoy

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            • #7
              sounds l;ike something i would get myself into . just one thing after another . and none of it good .
              im an american proud and free , a son of the south dont tread on me.

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              • #8
                Head came yesterday !!! Gotta say very happy w/ it. It was the head and cams. The seller also included all the bolts for both sides (intake and exhaust). This thing is super clean. I do have to scrape some old head gasket off but thats a no brainer. Hopefully i'll get it on today. However, i dropped oil pan to find that freaking copper washer and spotted it looking thru the starter gear side. After fingering at it a bit (hee hee)..it moved so i swapped positions to get at it and its disappeared !!! I REALLY hate those washers. Yet, in the oil pan i found a hex bolt AND a small phillips screw!!! Have NO clue about the screw...the bolt i can guess. Gonna check the fische's out before i reassemble.
                Thanx to kbcpartsnmore on ebay !! and thanx to DarkFury for the soon to be gas tank !!
                "The two most powerful warriors are patience and time!" - Tolstoy

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                • #9
                  OMFG !!!!!
                  I'm a firm believer this bike is cursed some how.
                  Dr. Frankenstein couldn't get this beast to live. In putting the new head on, got to the cam bolts (AGAIN).... and w/ torque wrench set at 6 lbs... Two broke off.
                  I did notice that they are not OEM bolts... i think they are aluminum or something.

                  I swear... i will need to take a few days off and avoid going thru my garage because if i look at this bike.. i'm gonna get my .45 out and put a few new holes in it.
                  "The two most powerful warriors are patience and time!" - Tolstoy

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                  • #10
                    That torque wrench of yours is getting you into trouble. 6 foot pounds is 72 inch pounds. You might want an inch/lb torque wrench for the little stuff. Torque wrenches can be way off at their extremes. Your torque wrench might be out of wack also.
                    1998 Suzuki GSX750 Katana
                    1980 Suzuki GS450ET
                    1977 Honda XL125

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                    • #11
                      LMAO.. it IS an inch/lbs wrench. I just did the conversion in my post.
                      Yeah.... i think its the bolts myself... combined with my burning desire to get this thing running.
                      lol.
                      But thanks for the confirmation on the conversion.... just in case i was having a senior moment.
                      "The two most powerful warriors are patience and time!" - Tolstoy

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                      • #12
                        WOOT !! Good news for today !!! My buddy took the head to a machine shop and the guy there was able to extract both broken bolts out no prob!!! Even dipped it to clean it !!!
                        FOR 0$ !!! Great to have awesome friends !!!
                        "The two most powerful warriors are patience and time!" - Tolstoy

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                        • #13
                          Its AAAALIVE !! ALIVE !!!! The zombie kat sputtered to life today!!
                          The beast awakens !! got a few leaks, squeaks, and what not...but its alive !!
                          My buddy helping me heard the #3 header leaking..Grr.. but thats prolly just the copper gasket needing changed. I also noticed the oil pan gasket is dripping in the left front corner. It felt like it was trying to strip out so i didn't over tighten til it completely stripped.

                          But overall she sounded strong, only couple valves were outta spec on the exhaust side. NO clue bout the carbs yet... i just wanted to hear it run !!!

                          Now to order oilpan gasket and some header gaskets.


                          New tank on the way and HOPEFULLY be here sometime around Thurs or Friday.
                          "The two most powerful warriors are patience and time!" - Tolstoy

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                          • #14
                            Yea my bike has been pretty smashed (not on purpose) but still trying to just find parts and do what i can to fix it

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                            • #15
                              Sounds like you have a bike like mine. Mine is called the Katastrohphe. The previous owner of mine wasn't very nice to it.
                              --- 1992 Katana stolen from San Antonio ---
                              --- Bought a 1996 Katana 600 ---

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