Katana of the Month - June 2007 - UPSMAN
 

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Go Back   KatRiders.com > Suzuki Katana Forums > Suzuki Katana Talk > Long Term Projects

Long Term Projects This is place to post up your long term projects. Projects that took you a while to get done. Post them here. Examples like kwebbel's build up , B-12 engine swaps, swing arm swaps etc..would go here.

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Old 02-14-2017, 12:30 PM   #1
derdmn
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Talking Restoring an 88 GSX1100FJ

So the owner of the local moto shop gave me a pre-employment project to complete. He had this bike in his graveyard and introduced it as a "shitbucket". Then he gave it to me

My 'job' is to get this machine running and driving and to show off my mechanical prowess and aptitude to earn a paid position in his facility. I am excited to 'own' another bike after i sold my first bike (a chinese honda clone 250) and glad to save a great machine with good provenance.

Anyways, this one has sat for many years. Front Master cylinder is siezed, I have that soaking to try and free up the piston and spring. Yesterday I pulled the tank and carbs to get the 'fuel'(if one could even call it that at this point)(it seems more like an actual shitbucket by looking inside) out and restored to an operable condition. After shaking some BBs and used gas i found a couple of seeping pinholes at the left front of the tank. Guess I will have to weld that shut before i continue the rust removal process as they leak enough to make a decent mess.

The carb rack is intact and complete.#1 and #4 had 'fuel' resting on the valves, and since there was so much water in the tank i fear the seats or the valves themselves may be compromised. Compression testing and leakdown testing will reveal any issues. We suspected the throttle cable was incorrectly installed, but in fact, all four throttles are frozen closed. the cable at the control moves freely and smoothly. If I understand correctly, these are 34mm flatside CV Mikunis. Should the 36mm carbs work as a backup upgrade if the originals prove to be junk? What about vacuum issues with the larger mixers?

She needs shoes and the shocks need rebuilt, any recommendations for modifications while I am in there?

I am looking forward to this build and riding again, though I have some trepidations at throwing my 5'7" 160lb self over the seat of a 150HP beast

heres a little Eye Candy, more pics to come as I spend more time with the bike.




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Old 02-15-2017, 11:02 PM   #2
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So today the master cylinder got unfrozen and disassembled, (ultrasonic parts cleaners are good stuff) and the tank got washed in prep for welding. Have a new piston and spring on order for the master cyl. rear should be fine with a clean and reassemble.

I did some heavy drinking last night in preparation for my 24th Birthday and woke up with a mystery head wound. Big hangover, so not much happened besides me hanging out in the shop and washing the tank.
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Old 02-16-2017, 12:00 PM   #3
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Old 02-16-2017, 02:41 PM   #4
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thanks shieplers
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Old 02-16-2017, 07:17 PM   #5
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I always enjoy seeing what people can do with basket cases, good luck.
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Old 02-18-2017, 08:03 AM   #6
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i did a bunch of stuff on friday 2/17. will post picture later.

gas tank is fixed. carbs are disassembled and cleaned.

have many pics to share.
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Old 02-19-2017, 03:22 PM   #7
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Default friday 2/17 image dump




















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Old 02-19-2017, 03:27 PM   #8
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Now that you've welded the tank, you need to seal it. You removed the galvanized coating inside the tank. POR-15 is a great tank coating.
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Old 02-19-2017, 03:31 PM   #9
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Default 2/17 explanation

disassembled carbs, put into sonic washer.they were very dirty so theyve been in the soup for three days now. welded tank. prepped master cylinder for rebuild, will look at caliper (FR) before completing system refurb.

tank went together fairly well considering it was mu first time welding on a gas tank. there were probably better options, considering i did expand the hole quite a bit, but the shop had just bought a new miller MIG machine so everyone was eager to try it. its functional, and now i can finish cleaning the crud from inside.

did a parts run to wally world, for those LED work lights which we installed in a couple of areas. They work so well, the plan is to get many many more.

the beer was for a little spring cleaning; with one mechanic recently leaving the shop, some shuffling and organizing was required. many beers were drank, and i built a rubber insulated rope handle for the wheelie trash can, since it is mostly my job to take it out when im there.

finished the night at a friends to play some King's Cup ( i like 5 - drive wonderful game) and the hat was a gift from my friend, its the shop hat.

Quote:
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Now that you've welded the tank, you need to seal it. You removed the galvanized coating inside the tank. POR-15 is a great tank coating.
the tank still needs lots of rust and crud removal before i can POR it. and our shop keeps KREEM on hand, so i will be most likely using that product. +1 on that advice though. You're very correct.

Last edited by derdmn; 02-19-2017 at 03:31 PM.. Reason: Automerged Doublepost
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Old 02-19-2017, 04:02 PM   #10
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Kreem is junk, it WILL peel off and has a tendency to dissolve. POR is like armore..
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