My 'project'

[the[K]id]

Though I should start posting, so here is what I have. It's errrr, a frame



Started out as a GS550M Katana purchased from fleabay, you know, something cheap and simple to learn to maintain and do a bit of commuting on.




Some spare engine bits sitting around and a minor oil leak lead to me deciding to pull the engine out, and I just kind of kept going. Leading to a shed looking a bit like this:



Have got hold of a 650 top end, and hunting down some new o/s pistons. End result should be a capacity just under 700cc which should make life with a frame design stuck firmly in the 50's interesting. Feel free to point out how much of a waste of space and money it is, most friends and family have done so already But at least it will be different. Plus rebuilding an engine is something I have always wanted to do, I am just glad its a nice simple of air cooled donk, its complex enough for now.

Will post more pictures as bits start to go back together. I think I still have another week of cleaning before that can happen.

Oh, did I mention I am hoping to get this back together for the MAD ride? Deluded doesn't begin to describe it...

[foolishboy]

Can I have some of what your on please???????

Seriously though welcome to PSB and all the best with your little project there, hope your able to have it back together in time for MAD.

[Deej]

Thanks for shareing.... look forward to seeing the end result.

Tex and I have always threatend we would rebuild a Katana... now we can live it through your thread and keep garage space and mariges at the same time!

[semi]

i love projects, need more of them on psb

[potato]

welcome along to psb mate !
nothing like a good tinker in the shed and i'm with semi ! should be more of this happening

[Rich]

Nice little project...look at doing a bit of bracing on the frame and fitting a more modern swing arm...Easy done and will improve handling...

[ritza350]

g'day kid ...label everything ,its too late to take piccies if you havn't already.....mike

[Rocket]

i love projects, need more of them on psb[/b]

Couldn't agree more ^^^^

Good work Kid, I like the tank and seats on those models, keep up the pics as you go along.

[Billywhizz]

Way to go

Streetfighter perhaps????

http://www.ratbike.org/docs/572.php

we have grinders and welders to suit all modifications

[Mr John]

Nice mess you got there Mr theKid, good luck with it

[fossil]

Nice project there mate, you cant go wrong with ol GS's
If you havent already, check out the forums at GSResources

I agree with the others in that we need more Projects on this forum

[Aphex]

Welcome to the nuthouse

By the looks of things you'll fit right in!

Look forward to seeing the end result at the mad ride.

Well done

[Turfie]

Nice one thats what shed's are for , (Big Brother of my little 2fidy - Blek also)....... Reminds me to get into the shed and start stripping down the old motor

[likefry]

nice work dood look forward to seeing the progress

i got me a 89 gsx600f katana .

try www.katriders.com its a forum in the USA on all types of katanas.

heaps of info on there and many many projects going on you could get some inspiration from.

[CitizenD]

Thanks for shareing.... look forward to seeing the end result.

Tex and I have always threatend we would rebuild a Katana... now we can live it through your thread and keep garage space and mariges at the same time![/b]

A Deej Industries sponsored build on the cards there?

[Falcore]

good to see mate

spose i should do an update on the rg's one day lol

[the[K]id]

Wow, didn't expect so much (well, any... haha) interest!

Thanks for shareing.... look forward to seeing the end result.

Tex and I have always threatend we would rebuild a Katana... now we can live it through your thread and keep garage space and mariges at the same time![/b]

Yeah, certainly does need a fair bit of space, time, $... But lovin it all the same.

Nice little project...look at doing a bit of bracing on the frame and fitting a more modern swing arm...Easy done and will improve handling...[/b]

I have read of a few others doing bracing on the GS frames, seems pretty straight forward. I am running K&N's which allows some of the rear bracing to be done. I'd like to fit newer forks as well as replace the swing arm and wheel, but that will probably be a 'next winter' item. Running gear off an SRAD would be nice, 17" rims and a 180 section rear would be too....

g'day kid ...label everything ,its too late to take piccies if you havn't already.....mike[/b]

126 pics and counting Got plastic tubs and bits everywhere, not to mention there is almost 2 and a half engines pulled to bits (GS550 complete, GS550 minus elecs, covers and carbs, GS650 barrels head and head cover...) so most of what is just lying around is just spare.

<div class='quotetop'>QUOTE(semi @ Aug 7 2007, 01:23 AM) <{POST_SNAPBACK}>

i love projects, need more of them on psb[/b]

Couldn't agree more ^^^^

Good work Kid, I like the tank and seats on those models, keep up the pics as you go along.
[/b][/quote]

Kat's are just such a classic, the 70's space ship with wheels look is fantastic. I liked the 550 with its funky tank and big single light front, kind of like a fightered up gixxer front.

Well, for those interested here is the complete rundown of my headache, oops, bike....

Engine is having GS650 barrels and head fitted, chasing down 1mm o/s pistons which will give it a neat 696cc (Anyone know someone reliable for a bore and hone? ). Carb's have been fitted with dynojet kits and K&N filters already. GSXR750 oil cooler will be going on, nearly the width of the engine its total overkill but looks phat! Every last gasket, o-ring and oil seal will be replaced.

Body work is standard for now, but am working on a composite tank to shave a few kg's off, plus the current one is at least 10% bog. Have a digital dash on its way to replace the way off speedo and horrid chunky idiot light cluster. Mini-indicators to get rid of that prince charles look. If in a good mood, I'll redo the wiring loom....

Frame has been stripped of its 'I once was black' coating and will be scotchbrited and laquered, engine will be gloss black with semi polished covers. Measuring up now to see if I can work out some mountings for rearsets as the standard footpegs are a touch low for my liking and have all the grip of an oiled ice rink.

I think I will be pushing $h!t up hill to have it ready in time for M.A.D. but I can dream haha. And if all this doesn't kill me, and the motor doesn't totally suck the next step will be some hot cams (web do some nice ones) and new running gear. I think I should have just bought a nice gixxer or something...

PS have pics of everything from rebuilding the carbs to the strip down of the engine if anyone is interested.

[the[K]id]

Well, after a few delays (biggest was buying a house, I know, excuses excuses...) the build up is back on in force. Have managed to get lots of small jobs sorted (various brackets, frame mods) and up to a point where it's ready to go back together, for now Already planning phase 2, but till then...

Piccie time

New digital dash


New footpegs


New vs Old, viva jenny craig mods



Never could get the bastard on the centre stand anyway...


New footpeg hangers, allow three positions, and home made brake master mount (for dinky little RGV job)



Mount for new dash



Frame back from sandblasters. Best money spent so far!


Put crank cases through works parts washer, before:

After:


Getting new shed set up, work bench coming soon:


Frame painted:


Engine getting set up for assembly:


Frame going together, with new bearings of course




Waiting on a couple of bits, but engine is 99% there and ready to go together. Can post pics of build if peeps are interested.
Specs are:
GS550 crank cases, modified to fit GS650 barrels
GS550 crank and rods
GS650 Barrels, honed
GS650 Head, tach drive removed and filled, have it at work about to be surfaced and will probably get the valve seats done.
GS650 pistons
GS550 cam shafts
Mikuni BS32SS carbs, K&N filters, Dynojet stage 3 kit

All gaskets, oil seals etc are being replaced. Every part has been pulled down and checked to ensure it's to spec before being reused (or replaced...). Should be pretty decent when it's together.

[Aphex]

Very nice. I cant wait to see the end result of this

Hurry up now ya hear

[Cam]

Very cool.