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Kat 750 TLC

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  • Kat 750 TLC

    So this isn't exactly a project bike. It runs ok now. It's more in need of TLC than anything else really. But F it. It needs all the TLC. And while I'm at it, all the goodies. Or at least a more than is really reasonable amount.


    Bought her last Saturday. Test ride was fine, little rough under 6k RPM, and horrible handling (it's a Kat, expected it). All moving parts were a little stiff from mostly sitting for the last 5 years. But the engine sounded fine, bike revved up without too much fuss, and could run without the choke being on once warmed up. So, $1500 seemed like quite the deal.



    Brought her home, did a more thorough investigation. Plastics in slightly worse condition than originally noted, but nothing that some plastic sheet and acetone can't fix. Paint is a little rough on one side where it went down at low speed, but meh...not really any worse than my old 600.



    Front tire has ~1/3 tread left. 5 years old, but garage kept. It isn't as hard as a rock, so I'm going to leave it for now. Rear tire, holy CRAP! Date code = 2000. That's right, 17 years old. Before my test ride, I noticed it was bald and a little squared off, so I was accelerating and cornering gently, but geeeeeeeze, that's gotta go. No more riding until that's swapped with a nice new PR4. On the schedule for this Saturday.



    All the lock cylinders were a bit stiff, so got a bit of graphite lube worked in. Much better now, particularly the ignition. Unlocking the steering stem doesn't feel like I'm going to break off the key in the ignition.


    Brakes were wooden, and fluid in the site glass quite dark. Bled those - better, but still far from where they could be. Going to swap to SS lines from G&J, planning to order those in the next few weeks. Used them for my 600 and 1100, love pricing and quality. Still need to grease the pad pins. It isn't notched yet, and want to keep it that way. Once that happened on my 600, filing the notches out was a bear.


    Oil changed. Duh, that was literally the first thing. Recepits that came with the bike had it at being changed 1000 miles ago, so it was still quite clean. However, it was also 5 years old. Filter is...really on there. I'm going to have to punch a screw driver into it to pull it off. I didn't have time to this time around. I'm going to do a shorter than standard change interval anyways, so leaving the filter on, especially when the oil was so clean, doesn't really concern me.


    In the process of figuring out the oil filter was stuck on, I was getting much more up close and personal with the headers. I think it might have a full exhaust system, not just a Yosh can. So, that's awesome.


    To do:
    New front tire

    Send Tmod my already resprung and valved shock (pulled it from the 600) for a rebuild

    SS brake lines

    Grease all the bearings - both wheels, swing arm, steering stem

    Pop my Corbin saddle on

    Lube all the cables. Choke isn't smooth, so I know that one needs it. If that does, throttle will as well.

    Install my 5* advancer (pulled from the 600)

    Rebuild forks - full works. Seals, bushings, and drop in racetech goodies. I was able to salvage 1 spring and emulator from the 600, other fork was too F'd up. So...really hoping I can buy just a single of each...
    If I can't...rebuild them and increase preload. And start investigating grafting on GSXR forks. Need to see how pricey that would be. Assuming 'new' forks would need a full rebuild, new springs, and different valving. That all gets kinda pricey, so we'll see. If I can get a single spring and emulator though, I'm pushing the easy button.

    Jet kit (factory Pro). Bike is running lean, pops on decel, and stumbles when accelerating though 6k. + why the hell not? Check A/F screw settings and sync while I'm at it.

    Shift kit (Factory pro). My 600 transmission started showing signs of weakening around 80k. Made it to ~130, but 2nd was starting to shift rougher and rougher. I won't have 100 mile a day commutes any more, so this bike will see a lot more shifting. Want to make sure I can still get tons of (s)miles out of it.


    Current Battery is only 7 months old, but it's a non name brand piece from an autoparts store. It's a lead/acid affair, so it won't last long. When it goes, going to try a Li-Fe battery. Have done, and loved gel based, want to try the next level and see if the $$$ is worth it.


    Fairings: I have a tail piece I picked up (had to buy a bundle of parts to get the 2 I actually needed), need to pull it out and see if it's the correct side and year range (98-02). If it is...SWEET! Install, and done. If not, fairing repair time.

    @Junker, you still have any kits left?

    The little teeny piece that connects the belly pan to the main fairing up front on the brake side has the upper mounting screw broken, so need to fix that too. Short term can just remove, but want to fix it right.

    Touring windshield. Always wanted one for my 600, but just never got around to it.


    Install harness for my Gerbing heated gear.




    Clearly that's not all listed in order of priority/ease/timeline. This thread will aim to document all of those things happening, + the usual maintenance thingos. And I still have the 1127 Chrome Project engine I bought from Mr Mohido a while back. Once the expensive bits are done on this bike, I want to send it to Holeshot and have them port the head. If finances allow...go to 1216cc. I'm making more now than I ever have, and am looking to keep up a nice trend of yearly increases for some time, so...I'm dreaming big. This 750 doesn't need much in the way of $ for upgrades as I was able to pull some from the 600, and several other things (SS lines, shock rebuild) I basically attribute to maintenance at this point. Would need both on a 20 year old bike. I spent ~2k for upgrading the 600. I've got $800 in left over insurance money and reusable parts for this one

    ***my image hosting site is being a little bitch right now. Pics will eventually be added.
    1998 Katana 750
    1992 Katana 1100
    2006 Ninja 250

    2006 Katana 600 RIP - 130k miles

  • #2
    Got it registered. Only had to wait an hour at the DMV. Was unable to get a tire on Saturday, will be the only thing on my to do list tomorrow (yay random days off in the middle of the week!)
    Was able to send my shock off to TMod for a rebuild. Soooo looking forward to dropping that in once it comes back
    Last edited by shpielers; 08-22-2017, 06:14 PM.
    1998 Katana 750
    1992 Katana 1100
    2006 Ninja 250

    2006 Katana 600 RIP - 130k miles

    Comment


    • #3
      Tire getting mounted. Turns out not only was the tire stupidly old, it was also the wrong size. So I'm guessing it didn't handle very well for pretty much....ever.

      Really glad I've got time today to start going over it a bit more. The rear brake torque arm nuts weren't tight. The rear hub would use some grease as the old stuff is looking a little dried out. The chain adjustment bolts were only finger tight. So....kinda wondering what all else I'm going to find.
      1998 Katana 750
      1992 Katana 1100
      2006 Ninja 250

      2006 Katana 600 RIP - 130k miles

      Comment


      • #4
        Crazy what you find going on with used bikes sometimes.

        The most recent local bike that dropped by for some parts... OMG, talk about a bike in need of some serious attention. Lol.

        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!"

        Comment


        • #5
          Didn't have to wait long to find the next thing - fuel leak. Need to pull the fairings tomorrow to investigate, but seems like it's coming from the tank or a fuel line since the entire #1 carb (top to bottom, from the limited view that I have worth the plastics on)
          20 year old lines, not terribly surprised. Should be an easy enough fix. Seems to be a decent leak though, down 1/3 of the tank after ~25 miles. Going to double check the fuel isn't ending up in the oil, but level in the sight glass looks to be holding steady.
          1998 Katana 750
          1992 Katana 1100
          2006 Ninja 250

          2006 Katana 600 RIP - 130k miles

          Comment


          • #6
            Looks like it's a leaky petcock. Rebuild kit ordered. Nothing ending up in the oil. Leak is getting worse now than it was a few days ago.
            Last edited by shpielers; 09-03-2017, 04:13 AM.
            1998 Katana 750
            1992 Katana 1100
            2006 Ninja 250

            2006 Katana 600 RIP - 130k miles

            Comment


            • #7
              Petcock rebuild kit came in yesterday, and I got my shock back from being rebuilt by TMod the day before. Got both taken care of today. Shock installed, and the dogbones pivot points all cleaned and regreased. Petcock was leaking fuel out the side, and was allowing a trickle to come out when in on or res with no vaccum applied. All internal rubber was shot. Also got the clutch adjusted. Productive day.
              1998 Katana 750
              1992 Katana 1100
              2006 Ninja 250

              2006 Katana 600 RIP - 130k miles

              Comment


              • #8

                @Junker, you still have any kits left?
                I can scrounge around and get one made up for you.
                Last edited by 92xjunker; 09-03-2017, 07:50 AM.
                "I'm sorry, I didn't mean to upset you when I called you stupid. I thought you already knew..."
                spammer police
                USAF veteran
                If your a veteran, join the KR veterans group

                Comment


                • #9
                  Oooooo! Thanks!
                  1998 Katana 750
                  1992 Katana 1100
                  2006 Ninja 250

                  2006 Katana 600 RIP - 130k miles

                  Comment


                  • #10
                    Replaced the broken rear clutch side fairing. Got a separate one years ago with a bundle of other parts, didn't need it then. Hung on to it anyways. Lo and behold, when I do need one, it's a) right color, b) right sticker c) right model. Seriously not sure why I kept it, wouldn't have been able to use it on my old 600, that was an 06 and the tail style changed in 03.

                    Took the rear apart, moved over the hardware/light and installed.

                    Checked for air leaks, none. Checked for a jet kit, none. Placed an order. Fyi...factory pro won't ship them to peeps in CA. But....eBay seller allegedly don't care..

                    Came across several bolts that were jacked from over torquing and/or missing washers/cushions. Ran them through a dye, ran a tap through the holes, much smoother now. Also need to order said washers and cushions. And a couple bolts that were just gone.
                    1998 Katana 750
                    1992 Katana 1100
                    2006 Ninja 250

                    2006 Katana 600 RIP - 130k miles

                    Comment


                    • #11
                      Ordered new windscreen that is supposed to be a bit taller. It's pretty cheap...so...not holding my breath, but we'll see.
                      1998 Katana 750
                      1992 Katana 1100
                      2006 Ninja 250

                      2006 Katana 600 RIP - 130k miles

                      Comment


                      • #12
                        FP jet kit in the mail
                        1998 Katana 750
                        1992 Katana 1100
                        2006 Ninja 250

                        2006 Katana 600 RIP - 130k miles

                        Comment


                        • #13
                          ...and it arrived!
                          This bike soooo needs it. Runs very lean, popping every time I let off the throttle. (And no, it does not have a k&n filter)

                          Also started regularly riding the bike to work regularly earlier this week. Had not been able to do so earlier because of the fuel leak, but since getting that fixed over the weekend
                          1998 Katana 750
                          1992 Katana 1100
                          2006 Ninja 250

                          2006 Katana 600 RIP - 130k miles

                          Comment


                          • #14
                            Windscreen arrived yesterday. Doesn't actually look as tall as I was led to believe via pics online, but like I said, it was cheap. We'll see how things work once I can get it installed.
                            1998 Katana 750
                            1992 Katana 1100
                            2006 Ninja 250

                            2006 Katana 600 RIP - 130k miles

                            Comment


                            • #15
                              Windscreen is the same size, but is more vertical than OEM (and double bubble).

                              Installed 5 advance - POS bolt holding on the timing wheel decided it wanted to become 2 pieces. So guess who had fun drilling the other half out...

                              Got the advancer in eventually. Started installing the jet kit. Holy crap carbs on the 750 are even tighter than the 600. Super hard to get the sync port caps off and lines to my manometer on. Need to make permanent pigtails...
                              Got the needles in, and that's really about it. Long day, very little progress.
                              1998 Katana 750
                              1992 Katana 1100
                              2006 Ninja 250

                              2006 Katana 600 RIP - 130k miles

                              Comment

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