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Cliff Notes:
Bought stock 91 Kat 600 late Summer 2007:
Wasn't in bad shape. Just needed a little bit here and there. It was slated to replace the commuting duties of the GS500E I had.
But of course all that went out the window when I found KATRIDERS...so just like every other project vehicle I've had...it got a little more serious..
I figured it would be useful for me to break it down from where I started. It will also help motivate me a bit...
Everyone blame Sport Drew for this. If I hadn't been seeing all the updates in his posts...this wouldn't have happened.
Tore the carbs off to diagnose the unsteady idle. Ended up fixing a lot of little things along the way.
Turns out a couple of my carbs actually had holes in the casting. This was causing issues with idle, that previous owners and "mechanics" had tried to mask by adjusting the Air / Fuel mixtures on different carbs.
Here's the poor Kat (it had no idea what it was in for)
- Ended up replacing the carbs with a used set I went through.
- Fixed airbox drain line
- Replaced all fuel / vacuum hoses
- Adjust valves
- Replaced valve cover gasket
- Installed shift kit in tranny
- Installed 98+ oil pan and pickup
- Installed Fumoto Valve
- Installed 98+ 750 header
- Installed 98+ Scorpion slip on
- Pulled swing arm
- Cleaned / painted
- Cleaned / lubed / checked all suspension bearings and points
- Installed Bandit 1200 shock
- New choke cable
- New throttle cable
- Rebuilt front and rear calipers
- New rear rotor
- Replaced master cylinder
- Stainless brake lines
- Speedbleeders
- Changed fork oil and added PVC fork spacers
Rode it like that for a good while.
Had a mishap loading it on a trailer after some shorted wires kept causing my main breaker to reset itself.
Since I had already acquired a 4K mile 01 Kat 750 that I Was parting out, it spurred me into action on swapping the 750 into my Kat
Got the bike painted. Long story short, I didn't end up paying a whole lot for the job done..he took a lot longer than he kept telling me. Not the color I Wanted...so I'll redo it myself.
Anyway here it is after the engine swap, fairing replace and paint.
- New Rear Z6
- White face gauges installed
And I'm sure some other stuff I can't remember
So May of last year...took a ride on the BRP...and after that this happened
So I put it back together again..
Painted the replacement fairing with rattle can to get it close.
Pretty much been riding it ever since...
I hate Winter...and the cold just saps my desire to do much of anything..but it's time to get cranked up..
Need to:
- Install the new front Z6 I bought awhile back
- Install the new exhaust mid-pipe gasket to fix the pesky little leak
Also install a new fairing stay. The one I ended up using is tweaked a bit. Didn't realize it until I got all the fairings back on. I'm waiting on a straight part right now.
While it's apart I plan to:
- Wire up the 98+ control pods I've had forever. In fact I have one wired up already to a pre 98 wiring connector I had laying around.
- Install a undented gauge bezel on my gas gauge (dented during the wreck last year)
- Install the new air filter I've had sitting around
- Install the Ivan't jet kit and see what happens this time
There are few other things as well.
In the past year I've gathered enough spare parts so I can put a real paint job, myself, on those parts while still being able to ride....
So that's it. My attempt to motivate myself.
Now..I'm off to shovel snow.
Did I mention I HATE WINTER?!?!
Bought stock 91 Kat 600 late Summer 2007:
Wasn't in bad shape. Just needed a little bit here and there. It was slated to replace the commuting duties of the GS500E I had.
But of course all that went out the window when I found KATRIDERS...so just like every other project vehicle I've had...it got a little more serious..
I figured it would be useful for me to break it down from where I started. It will also help motivate me a bit...
Everyone blame Sport Drew for this. If I hadn't been seeing all the updates in his posts...this wouldn't have happened.
Tore the carbs off to diagnose the unsteady idle. Ended up fixing a lot of little things along the way.
Turns out a couple of my carbs actually had holes in the casting. This was causing issues with idle, that previous owners and "mechanics" had tried to mask by adjusting the Air / Fuel mixtures on different carbs.
Here's the poor Kat (it had no idea what it was in for)
- Ended up replacing the carbs with a used set I went through.
- Fixed airbox drain line
- Replaced all fuel / vacuum hoses
- Adjust valves
- Replaced valve cover gasket
- Installed shift kit in tranny
- Installed 98+ oil pan and pickup
- Installed Fumoto Valve
- Installed 98+ 750 header
- Installed 98+ Scorpion slip on
- Pulled swing arm
- Cleaned / painted
- Cleaned / lubed / checked all suspension bearings and points
- Installed Bandit 1200 shock
- New choke cable
- New throttle cable
- Rebuilt front and rear calipers
- New rear rotor
- Replaced master cylinder
- Stainless brake lines
- Speedbleeders
- Changed fork oil and added PVC fork spacers
Rode it like that for a good while.
Had a mishap loading it on a trailer after some shorted wires kept causing my main breaker to reset itself.
Since I had already acquired a 4K mile 01 Kat 750 that I Was parting out, it spurred me into action on swapping the 750 into my Kat
Got the bike painted. Long story short, I didn't end up paying a whole lot for the job done..he took a lot longer than he kept telling me. Not the color I Wanted...so I'll redo it myself.
Anyway here it is after the engine swap, fairing replace and paint.
- New Rear Z6
- White face gauges installed
And I'm sure some other stuff I can't remember
So May of last year...took a ride on the BRP...and after that this happened
So I put it back together again..
Painted the replacement fairing with rattle can to get it close.
Pretty much been riding it ever since...
I hate Winter...and the cold just saps my desire to do much of anything..but it's time to get cranked up..
Need to:
- Install the new front Z6 I bought awhile back
- Install the new exhaust mid-pipe gasket to fix the pesky little leak
Also install a new fairing stay. The one I ended up using is tweaked a bit. Didn't realize it until I got all the fairings back on. I'm waiting on a straight part right now.
While it's apart I plan to:
- Wire up the 98+ control pods I've had forever. In fact I have one wired up already to a pre 98 wiring connector I had laying around.
- Install a undented gauge bezel on my gas gauge (dented during the wreck last year)
- Install the new air filter I've had sitting around
- Install the Ivan't jet kit and see what happens this time
There are few other things as well.
In the past year I've gathered enough spare parts so I can put a real paint job, myself, on those parts while still being able to ride....
So that's it. My attempt to motivate myself.
Now..I'm off to shovel snow.
Did I mention I HATE WINTER?!?!
1991 Katana 600 - sold 
this is the best icon eva
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