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I bought a Kat cause it was in my price range.

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  • I bought a Kat cause it was in my price range.

    Hey, my names Paul. I live near Seattle. I recently moved from Kansas City. I've been riding on and off for about 18 yrs. I had an 05 r6 for years.
    I picked up this pre Kat from a place called bent bike, knowing it was a project. Boy, did they live up to the name. This bike had so many problems I'm sure I'll forget to mention them all. The engine ran Ok 30k on the odometer. It's a 93(at least the frame is). It's been dropped a few times. The stator cover was pretty gouged. I replaced that. The clutch didn't work because the clutch lever/cover on the left side of the engine was broken and barely bolted down. I replaced that, as well as soldering the neutral safety switch wire back on. While I was there I pulled the clutch basket out, everything in there looked great. I pulled the valve cover and checked the valve clearance. All were in except 4 in the front center. So I reshimmed those. Replaced plugs. Checked carb sync. Replaced the broken swing arm. Put a new rear shock on while I was in there. Found a couple missing pieces, like muffler hanger. Fixed the kick stand by welding it up and refitting it, it works like new now. Overall just anything mechanically wrong I could find. Replaced the oil pan gasket.
    I worked on it on and off for a few weeks before it was ready to ride. I drove it home yesterday and today. I took it for a couple mile jog up the hill and on the way back down, I was on it pretty hard in first gear. I hit redline and it shut down and wouldn't restart. I thought for sure that the valves smacked the Pistons. I got it back to the shop and started pulling plastic and a piece of the new stator cover fell out on to the floor. The bolt holding the reluctor wheel on the shaft came out and went straight through it. I tightened it back up and it purred like a kitten. I just reJBwleded the gouged cover for the moment until the new cover arrives.
    All in all I'm happy with the bike and I know it like the back of my hand. Thanks to all before me, this site has Helped emminsely.
    Attached Files
    Last edited by Techb; 04-14-2014, 09:50 PM.

  • #2
    Welcome to KR! Sounds like you're well on your way to getting her back in shape.
    sigpic Mulholland Hwy Ride
    1992 Katana GSX600F (on permanent loan to a family member)
    2000 Suzuki Hayabusa
    First Hayabusa Commercial Hayabusa Design
    Hayabusa #1 Wonder of Motorcycles

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    • #3
      Welcome!
      1998 Katana 750
      1992 Katana 1100
      2006 Ninja 250

      2006 Katana 600 RIP - 130k miles

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      • #4
        Now it won't shift

        So, I got the old cover back on. Rode it home today and it started skipping like a loose chain. Not loose at all. Now it
        Won't shift into second at all. I'm assuming it's a bent shift fork. Hopefully not broken gears. How hard is it to fix the shift forks? And threads that have been over this? I haven't dug very deep into a transmission, looks like I'm about to learn some more.... Yay.
        Last edited by Techb; 04-14-2014, 11:28 PM.

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        • #5
          Lots of technical stuff here on the site it's been a big help to me and did I forget to say it welcome to kr

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          • #6
            Originally posted by Techb View Post
            So, I got the old cover back on. Rode it home today and it started skipping like a loose chain. Not loose at all. Now it
            Won't shift into second at all. I'm assuming it's a bent shift fork. Hopefully not broken gears. How hard is it to fix the shift forks? And threads that have been over this? I haven't dug very deep into a transmission, looks like I'm about to learn some more.... Yay.


            It's not that hard really. There is a nice detailed post by user Manny a while back when he went through his. It's just a lot of work as you need to remove the engine.


            Krey
            93 750 Kat



            Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

            "I've done this a thousand times before. What could possibly go wron.... Ooops!"

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            • #7
              Ok, so I got the engine upside down and started messing with the shift forks.the one opposite the clutch basket was completely jammed. After some coaxing with a brass drift and a slide hammer beating on vice grips I finally got the cracked shift shaft out. The jammed fork was scarred and discolored from rubbing the gear. I'll try to remember to take pictures tomorrow. I'm gonna measure all the shift forks and Def replace the one. I'm contemplating getting a shaft made from solid steel instead of that hollow Pos. Any suggestions for cheap upgrades while I'm in this far? I'm ordering all the seals and gaskets (most of which I just replaced after waiting for from Japan it seemed). Anyone else had this happen? I've also got one slight problem. The ratchet mechanism on the shift fork guide fell and went everywhere. I've got it figured out for the most part, but there is one spring I can't find a home for. The two in behind the ears are still there. I haven't spent a lot of time yet but I may need a new spring for my ball point pen anyway.

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              • #8
                Welcome!!!

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                • #10
                  But where does the lone spring go?
                  Attached Files

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                  • #11
                    Originally posted by Techb View Post
                    But where does the lone spring go?


                    2 springs, 2 pauls that go with. Looks like one spring is still stuck in the larger part?


                    This might help. The assembly is in the upper left.





                    Krey
                    93 750 Kat



                    Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

                    "I've done this a thousand times before. What could possibly go wron.... Ooops!"

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                    • #12
                      Is there any way to move this to a different category? Project or mechanical?

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                      • #13
                        That's one hell of a project. Good luck with it and keep posting updates!

                        Knowing Bent Bike, they probably wanted $4k for that, didn't they?

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                        • #14
                          Originally posted by Techb View Post
                          Is there any way to move this to a different category? Project or mechanical?


                          I'd just suggest making a new post with a brief history to date if you have more questions.


                          Krey
                          93 750 Kat



                          Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

                          "I've done this a thousand times before. What could possibly go wron.... Ooops!"

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                          • #15
                            Originally posted by elsueco View Post
                            That's one hell of a project. Good luck with it and keep posting updates!

                            Knowing Bent Bike, they probably wanted $4k for that, didn't they?
                            They were asking 1900. I offered 900.they came back with 1600 I paid 1350 out the door with taxes and license.

                            I knew it was gonna be a project, I just didn't expect to have the motor upside down after my second ride. To be totally fair, today they offered me another motor for free if I need it. I'm sure I do now that they mention it
                            Last edited by Techb; 04-17-2014, 09:13 PM.

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