GSXR 750 into '90 Kat 600 - UPDATED! Mar2 '06

[Grimmy]

Here we go!

I picked up my engine last night from niagara falls - I had this thing sitting down there for over 2 months! YAAAAAY!

Now to do the hard long, tedious work of doing its engine maintenance, valve lash adjustment, lubing, penetrating fluid in the cylinders, oil change, pressure testing the oil cooler... and manually turning it over...

Then installing it, getting and tuning carbs for it, and running it, and further tuning on a dyno!

Wow! sounds like alot of work!


-Grimmy

[Black_peter]

niagara falls!
Slowly I turned....



(I know at least 4 people here that know that one!!)

[Darren]

Re: GSXR 750 into '90 Kat 600

Here we go!


Wow! sounds like alot of work!


-Grimmy

Or A lot of FUN.....

[illinoiskat]

What year 750 is it?

[woobie]

Sounds like you have some fun ahead of you ?

[md86]

niagara falls!
Slowly I turned....



(I know at least 4 people here that know that one!!)

Inch by inch ....step by step .... Even close ?

[Grimmy]

slowly I turned??? I dunno....

Engine installed! Didnt take much time - all engine mounts swapped right over from the 600 to the 750 - no issues what so ever.

Mounting the larger, (and curved) oil cooler will take some inventiveness, but I think I already have a solution figured out.


oh- the engine is from a '90 GSXR 750.

-Grimmy

[Grimmy]

The list so far of stuff done... alot of work. My brother and I cracked off over half of this in one 12 hour day. I was damn dirty at the end of the day, I tell ya.

-Grimmy

Completed

-Removed Rear brake assembly (Black Tokico)
-Replaced rear brake assembly (Gold Tokico)
-Installed new rear brake pads
-Flushed Rear brake lines with new fluid (Dot4)

-Removed Front brake assembly's (Black Tokico)
-Replaced Front brake assembly's (Gold Tokico)
-Serviced front brake assembly's (pads still good 60% pad remaining)
-Flushed Front brake lines with new fluid (Dot4)

-Removed, Cleaned and lubed speedo cable
-Cleaned and lubed speedo sender

-Removed rear suspension and swingarm
-Inspection of all 6 needle bearings and re-pack
-Prep and paint rear swingarm
-Reinstall rear suspension and swingarm and torque to specs
-Adjusted rear suspension settings (5of7 & 3of3)

-Removed, Disassembled, cleaned and reassembed rear wheel
-Removed, Disassembled, cleaned and reassembled front wheel

-Raised front forks back to stock height (1/2")

-Removed exhaust system
-Removed final drive chain
-Removed Airbox, Battery box, Tank mount
-Removed Carbs
-Removed GSX600F engine and cooler
-Removed bike wiring harness
-Removed Seats
-Removed Tail lamp assy
-Unmounted GSX600Fengine from lower subframe

-Inspected Cam adjustment (shim type) on GSXR-750 engine
(All within spec, 1 Intake cam and 2 exhaust cam at upper allowabile limit.
Will need new shims at end of 2006 season)

-2cc's of penetrating fluid inserted into each cylinder
-Hand crank of engine, engine play is free, and relatively easy with plugs not installed.

-Mounted GSXR-750 engine into lower subrame and torqued
-Adjusted Carb cable to fit frame clearance allowed
-Installed GSXR-750 Engine into bike frame
-Temp install of oil cooler
-Removed Signal Generator and plate from GSX600F engine
-Insalled Signal Generator and plate from GSX600F into GSXR-750 engine
-Installed wiring assembly and remounted all electronics after cleaning
Question: Will the GSXF600 Signal Generator run the GSXR750 engine with the 600 wiring and CDI???
I noted that the GSXR750 signal generator connectors were not the same as the 600, and a full swap was easier than splicing)

-Oil change
-Inspected sparkplugs - near new - cleaned and re-used

-Charge old battery - Not holding sufficient charge
-Replaced Supheric acid in battery and charge - still not holding sufficient charge

-Test start bike with no carbs or exhaust.
(No issues, bike is loud cranking over. Oil light turned off after 15+ cranks)
-Test Start bike again 1 day later, still loud, oil light turned off after 5 or so cranks)

-Body Work - complete
-Color sprayed - complete save for 1 peice needs respraying (Radiant Silver w/ metallic)
-2 coats color (2000 grit wet sanding between sections)
-Clear coat sprayed on all tail sections.

TO BE COMPLETED

-Carbs installation
-Exhaust Installation
-Clear coating, final wet-sanding and highspeed polishing
-New exhaust gaskets required
-New windscreen required
-New right mirror required
-Final assembly
-New battery required
-New tires 2,000km max left on current tires (track scrubs are $75.00 for pair)