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Oiler Boilereerer...er(s)
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Discussion Starter · #1 · (Edited)
venturesomerite's Uglier Betty - 1996 Katana 600 - 2015 Build off - BUILD THREAD

OK so fuck it, I'm in. I say that like every year, and never finish. So what's the harm, most people don't anyways.

So most of you probably know, I've been working on this same hateful japanese thing for years now, and I change my mind more than I accomplish things.

For those who want to see what I have done, then undone, and redone only to re do again in the past, here's the thread. Poke here for a sad story


Anyways, if you browse thought the old thread, you will notice 2 distinct things (A) I have no fucking money, never have, never will. It's very rare that I can buy something new, usually I have to beg, borrow, steal or make it. (B) I CANNOT stick to a plan, whatso ever. I am not good at planning or sticking to it. I just kinda do what ever the fuck I feel like at the moment, which is why the bike still is not done, and has like nothing to show for it. lol


My tools are decent, but I do not have a lathe, or mill. If I did, my shit would probably look alot nicer lol.


Ok Pics below. Here's how she currently sits, and you can see that the date stamps on my camera that I use for work are right, I'll probably use that to take pics as it takes better pics and I can kinda document when I did what, and it's also much faster to upload.


























Work that has been done that will remain unchanged for this project Transplanted un running 1986 GSXR 750 motor (has 96 kat 600 carbs on it right now, it would fire, but you couldn't run it) relocated ignition to side under petcock, made custom exhuast, other than that, I plan to fuck with everything else.

you can see I have some boxes of shit I might use, might not. Not sure yet.
 

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Oiler Boilereerer...er(s)
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Discussion Starter · #2 ·
THIS PART YOU CAN IGNORE, it's just my running check list of things I need to do so I can keep track. Going to update it so I can keep track. Can't loose the list this way. :)

I'll keep a list of what I buy here. Anything not listed that appears in the build either I made with materials I got for free from somewhere, or a part that I had in my stash somewhere.



$512.00 - Flat slides, and push/pull throttle cable housing, pod filters
$15.79 - Engine case bolt kit
$190 .00 - Cooler, lines and fittings (braided and AN)
$24.47 - Generic 1 wire o2 sensor, and weld on 45* bung.
$19.97 - Gauge cup for my A/F gauge
$48.99 - Indicator surround for trail tech Vapor
$23.00 - fork clamp
FREE - Steering stabilizer - (I think of a 02ish GSXR) - came with box of parts
FREE - Rear sets, got them from someone on this site some time ago, can't even remember what they are off of
$74.52 - Dan moto adjustable clip ons - Black
$24.00 - Urine sample master cyl
$15.49 - Front and rear brake pads
$274.92 - custom front brake lines, throttle cables, and clutch cable.
$12.95 - Replacement rotor bolts (mine were fucked)
$21.88 - Fork Seals
$17.93 - New header wrap
$7.00 - Oil pan gasket
$50.00 - Rear swing arm - Kat 750 widened
$100.00 - 94 GSXR Rear wheel, brake caliper, caliper mount - Traded a frame for these (valued at about $100)
$30.00 - Pocket Bike ail fairing and SV650 Brake light.
 

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Oiler Boilereerer...er(s)
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1,562 Posts
Discussion Starter · #3 ·
I figured I'd start off on a good foot. Orders some parts on the 'ol credit card, still gotta order alot more, and some that are alot more pressing and important than the shit I actually orded lol.

Modified my old headlight/blinker bracket for Kat 600 tripples to fit my GSXR lower tripple. Drilled and tapped some bolts and it's good to go. Only mock up, will paint and lock tite for final assembly.















Once that was done, I moved on to figuring out the steering damper. I've had one for a long time, I think it was off around an 02 GSXR, but I'm not too sure. Either way it's going on. I started off by removing the forks, then I shaved off the old remnants of the stock bracket, I think it was a mount for the headlight. I also shaved off the old steering lock. Being real careful not to get rid of the VIN #. I also took off the ugly stickers that were on the head tube and both sides of the top frame tubes.


Fabbed up a bracket to mount to the head tube.











THIS is a really good example of why I made up a stand to cradle the frame while the bike is on the lift back wards.






Then I tacked on the bracket, and rigged up a nut and hose clamp to act as a stand in for my fork clamp until it arrives.








Also plopped the tank on to have a look see.








Then I got to thinking, I might run these silver forks instead of the blues. Either way, they need a rebuild. I need your input CF, which ones? TELL ME HERE WHICH FORKS YOU PREFER. Keep in mind the bike will be mostly semi-gloss black, with the orange accents.


 

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Oiler Boilereerer...er(s)
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Discussion Starter · #4 ·
Thinking of running these clips ons. They will give me the feel of a drag bar, but will solve the clearance issues, as I'm probably going to need to lower the front end some, which will shove the forks back up into the bars. Although I really want a set of bars, I do like the adjustability I would have with these. And I hate having the bars real low, like normal clip ons under the tripple.


LINK TO CLIP ONS
 

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Oiler Boilereerer...er(s)
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Discussion Starter · #5 · (Edited)
I have been spending some time day dreaming and trying to source parts for lines and a cooler upgrade.

I have found everything I need, just trying to settle on a cooler. I think that I will end up using a thicker, narrower one than stock, as that seems to be what's available, and most importantly, in my budget. I'm thinking I'm going to end up making some mounting brackets to utilize the stock upper mounts, and then just make new lower mounts.


Im happy that they make AN fittings in black now, because I fucking hate the blue and red ones.

I've ordered carbs, clip ones, brake pads, new master cyl and res for the front brakes, and also a new engine bolt kit thus far. I also bid a on a seat, but well see if it get it.

EDIT: Fuck it, I just bought the shit for the cooler, and an o2 sensor and bung for my A/F gauge I've had forever and never done anything with. That's what credit cards are for, right?




On a parts note, anyone know of a keyless gas cap that will fir a 96 Kat tank, I've only been able to find ones that fir 99+ kats. They might fit, but I've never really looked at a post Kat tank too well to know.
 

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Oiler Boilereerer...er(s)
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1,562 Posts
Discussion Starter · #6 ·
ok, gotta type this shit again cause Pandora froze my comp.




I got some shit in the mail, Brake pads (lotta fucking good that does me right now...) and the fork clamp for my stabilizer.






AND for anyone that was thinking about buying a protek clamp, this is the fitment/alignment straight out of the packaging.












Except, like an asshole, I ordered a 53mm instead of a 54mm. So I kinda thought "well that sucks"....then I thought "fuck that shit, it's going on one way or another!"



So then I spend hours in CAD drawing up a plan, and then got in on the mill for a line hone.....











So really what happened, cause I ain't got all that fancy horseshit, Is I took a die grinder and a angle grinder with a scotch brite roloc and I just ground a little at a time until it clamped like a champ.

I also got rid of the logo cause I ain't a billboard.














Then I had to space this guy up a little because he's not threaded the whole way up.





And then she's on. Pivot is great, no binding. I think I am gonna put heavier fluid in it though. Gonna wait till i can actually ride it to make that call though.










And that's it till more shit comes in. Guess I might paint the front wheel or something next. I do have to get the steering stops sorted out too, I guess that's kinda more important...
 

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Oiler Boilereerer...er(s)
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1,562 Posts
Discussion Starter · #7 ·
Got some presents from the mailman and the big brown truck today! Just want to say thanks to JackstandJohnny for sending me this boss Barbie beach towel with my parts, and also for the stickers and button!











Fist I did a quickie mount of the A/F meter, this isn't how it will be mounted, but it's the general gist of it, and area.








Then I got to work, took off the exhuast, cooler and lines, and dropped the pan so see what's up with it. I have to say, this fucking mount thing I made is really tits right now, as I can still work on the bike on the stand with no front end and drop all this shit from the bottom! Gotta see why it's leaking oil.









Then I started making a mount for my new cooler. Gotta make some custom brackets to put it where it needs to go, as well as to utilize the stock upper mount. Pics kind speak for themselves. I should note, I added rubber between the mount and cooler on both top and bottom to minimize vibration to it. Ended up chaning the design as I went, but overall I'm happy and it will work just fine.































 

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Oiler Boilereerer...er(s)
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1,562 Posts
Discussion Starter · #8 ·
Got to work on mounting up the cooler.

First, I put the wheel back on so I could see the spacing. Then I put together the fittings for the cooler lines so i could make sure they don't hit shit, since these coolers are typically run on GSXR's, which have a WAYYYY more forgiving frame set up for where the lines are. This shit is real tight on a kat, but god damn apparently it CAN be done. I spent forever picking a spot and turning the forks, then it slipped, so I reposition and rinse and repeat for like an hour. Finally I got close, and was able to use some foam and sip ties to space it away from the header and hold it where It should be (roughly)




Then I got to work making some upper mounts to utilize the stock kat mounting spots for the cooler. Nothing fancy, just some rod I had around and some nuts.












Then, fuck me, I realized that the lower mounts were on the outside of the cooler, and the big old dogbone looking thing I made for the bottom of the cooler was useless. So fuck that, I cut it up and made it continue life as cooler mounts in a different conficguration.









Then I realized that the lower mounts looked like donkey balls, so I dressed them up some.








and so this is what I ended up with. As you can see, the shit is real tight in every possible spot, but nothing hits, and it will work just fine. Also, fuck doing that again.






















Which left me with this.


 

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Oiler Boilereerer...er(s)
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1,562 Posts
Discussion Starter · #9 ·
So of course, then I decided I really didn't want the damper on top of the headlight, so I had to make a bracket to hold it to the fork bolts.















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So I moved it around 500 times, and finally found a spot that din't bind or hit the forks at full steer in either direction. So I cut the stem tab a little smaller, and welded her on.


Then I just bullshiteed a quick zip tie and aluminum bracket to stick the headlight back on. This is roughly where I have to mount it. I can't got closer to the bike, or lower or it will hit the damper.







So now I'm kinda thinking about shopping for a new headlight. Any suggestions?
 

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Oiler Boilereerer...er(s)
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1,562 Posts
Discussion Starter · #10 ·
Got some little bs started tonight.

Cleaned up the oil pan, can't find any cracks. Gotta check the block for cracks now I guess....





Also took the front calipers apart for rebuild, looks like I should just do a full rebuild on them




Got my banjo adapters in. Damn were these hard to find.






and bad news bears, I wanted to test fit my flatslides, and they physically do not fit onto the bike. The boots fit both bore and carb alignment, but the carbs are too deep, and the bowls hit the alternator mount bolt on the top. I also found that one bowl bolt on the bottom was ground for clearance on something, so I'll have to replace it, as it's ground right through to the inside. One of the three has been replaced with a lower profile head, which I'm going to try and match as a start for my clearance issues, but It looks like I'm going to be eating away some of the alt mount until it fits.











 

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Oiler Boilereerer...er(s)
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Discussion Starter · #11 · (Edited)
Not a big update, but an important one to the build.


First off, my new front master came in. So first order of business was to swap out the lever it came with for my old orange one. Easier said than done. Problem was that I couldn't sawp jsut the lever, I HAD to keep the pivot that the lever was attached to because the plunger pivot that came with the new master it totally different, and even the bolts holes are way different. When the pivot that the orange lever was in is mounted up, it depresses the plunger in the not touching the brake resting position, so that ain't gonna work.

I ended up finding a easy solution, I shaved down a few parts of it. 20 test fits latter, it's on and will work as it should. I also mounted up my new on/off switch, and my push pull throttle assemblies.
















Which brought me to my next project for the night, trying to figure out the flatslides, and why they won't fit in. The carb alignment was perfect, but it was like they were too low. After talking with Jackstand Johnny, he mentioned he thought they were off a built 11xx cc, which he believes has a taller head, which I seem to recall reading is true, so that's probably where my clearance problem came from.



So I swapped the boots all around, ( I knew it wouldn't work, but I had to try any ways cause that's free) hoping some configuration would raise them slightly, but as I thought no, and even if it did, I need the boots to be in the right spots to straigten out the factory angle on the block.


So my ultimate solution was to shave some off the alt mount, and the bolt head, gaining me just enough room to squash those bastards in there. It's tight, but they go in and that's all I give a fuck about.







You can see here, once they are in, there plenty-o-room, but on the angle they go in at, not so much.




So then I plopped the pods on, only to see that my CDI is in the way of the RH most one, so I just flipped them all upside down. Fuck it, look fine to me.:rock:






Then I hooked up the cables and got them all set. They seem to work best when you don't put the push in the pull and pull in the push, go figure lol




So of course, I had to throw the tank back on to take a look, and I'm glad I did. The petcock occupies the same space as the push/pulls.



 

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Oiler Boilereerer...er(s)
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Discussion Starter · #12 ·
Got my new clip ons in today, very stoked about them, fit well, finish is good and they even came in a box with all sorts of fancy Chinese writing on it.

Problem is the directions say I can't install them. Poo.










Oh wait, fuck that. Directions aren't meant to be followed, especially on fighters:skully:


So I got to work, swapped out the forks for the silver ones just for fun, I think I'm gonna run these and save the blues for my bobber in the future.
















Gotta sort the clutch cable in the future.







As you can see it really drops everything down, low and mean the way I like it.






Just a mock up position, but these things are like inifinately adjustable, so I can dick around with it once I can actually sit on the bike and feel it out. They clear the tank with plenty of room as is, so I'll probably leave 'em close to where they currently are.










So I got to thinking how I'm gonna mount my trail tech now, since I WAS using the bar clamp mount. Me thinks I'm gonna mount the A/F gauge and the trailtech on the tripples, with some custom made brackets. You can see the A/F just mocked up using the crappy steering column mount I have for the pod.








I also Got my seat in. Honestly, It's about 30% bigger than I thought it would be. I'm really not sure if I'm gonna use it, mod it or just sell it. It's literally mint, so selling shouldn't be an issue. Liberally use of custom green mock up tape used.




 

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Oiler Boilereerer...er(s)
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Discussion Starter · #13 ·
Not satisfied, I got a little more done. I don't have the resources to fuck with the gas tank right now, Though I do plan to in the futures, I decided to just make the carbs and petcock live nicely together.

I opted to make a new bracket, rather than modify the old one because I do plan to make a tank at some point in the future, and I'm saving this bracket to just put back on when that time comes. More work now, but a pay off then.


So I started with the same plate that I've made pretty much every bracket from so far.
(for anyone curious, I snagged it from a job I had. It's the cover panel for the dessicant wheel access hole on an ice rink dehumidification system)





Original Bracket






The problem:






CAD blue prints





First test fit, and so on. You guys can figure it out.

















Here's a good shot of the difference in the cable entrances between the two












Then I needed stops for both sides, so these were chosen to be sacrificed, then I chose a different large bolt so I could adjust it with a wrench from the side, rather than a screwdriver from the top.







(YES, I know I need a new bottom cable. :) )

 

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Oiler Boilereerer...er(s)
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Discussion Starter · #14 ·
got my trailtech dash surround in, so I started fucking around with that. That led me to finally having to fuck around with the upper tripple, and fixing the holes in it, as well as shaving the ignition bits off. I ended up taking it to a friends to sandblast it and use a spool gun to weld the holes up.



















Got to work on the tripple. The black came right off. The green took fucking forevererer!
Who the fuck paints Suzuki parts Kawasaki green anyways?























Came to realize a few things I'm gonna have to do:

1) Make my own mount for the trailtech, the one they provide won't work.
2)I have to extend all the wires for the dash and the surround lights, as ALL the connectors will be visible.
3) I have to go back to a side mount option for the A/F gauge, as the surround for the TT is too wide, I thought it would be a smidge narrower than it is, so they won't play nice on top. It's ok, the TT looks really good up there by it'self.
 

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Oiler Boilereerer...er(s)
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Discussion Starter · #15 ·
Got some work done on the gauge today. Started off by shaving the last two mount pieces off the bottom on the tripple. I was saving them incase I needed them, but I don't so off with 'em!









Then I fabbed up a bracket to hold the trailtech where I wanted it. I also drilled at tapped two holes for the mount on the bottom of the tripple. They ended up basically where the ignition mounts were.

I opted to angle it up in the front to mimic how I always ran it when i had the bar mount. I couldn't see it well when it was flat.

For anyone curious, the little rubber guys with the red insets and those allen cap bolts are off of the univeral tail tech mount that came with the surround. The other ones used to mount the bracket to the tripples are just two allen caps that i had laying around from an electrical cabinet I scrapped but pulled all the hardware off of first :)







Test fitting. One of MANY






Custom bending device.







And a working Bracket.








So as you can see, that doesn't look too pretty from the front. So I dressed it up a little with some sheet metal. Wish I tested it to see if it was stainless steel BEFORE I went to weld it...lol.

I didn't take a picture with the leads for the idiot lights plugged in, but it looked even worse.












I did add a little tab to connect the top of the bracket to the face piece, but I guess I forgot to take a picture of it.
So now we just skip to a primmed, not finish sanded piece in mock up stage. I will finish the body work on it when I go to do all my painting. I also have to true up the top edge, as I noticed when mounted it dips in the middle, but that aside, I'm pretty happy with it.

I think it cleans up the look pretty nicely. Utilizing the half round cut out in the tripple where the ignition used to be turned out work out really nice.


OLD BRACKET FOR REFERNCE






New Bracket



















 

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Oiler Boilereerer...er(s)
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1,562 Posts
Discussion Starter · #16 ·
Replaced the bolts on the side covers with some SS ones. Somehow I ended up with two extras (IKEA bolts?)

I had to shave about 1/4" of threads down on one of bolts for the LR cover so I could get it to work, probably as a result of me swapping the motor from hydro clutch to cable clutch, but whatever.















 

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Oiler Boilereerer...er(s)
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Discussion Starter · #17 ·
Haven't touched her lately, Been super busy trying to stay above water lol.
 

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Oiler Boilereerer...er(s)
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Discussion Starter · #18 ·
Holy shit! Haven't touched the bike, this snow has been keeping me really busy, which I can't complain about. Pays the bills after all.

Hoping to get some time in this month, still ALOT to get done!
 

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Oiler Boilereerer...er(s)
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Discussion Starter · #19 ·
Ok so I did something, even if it's not work.

I ordered up some brake lines to fit my needs, and also got a throttle cable kit as well as a clutch cable kit.

Clutch cable won't clear fork set up with the stock katana bend it has, and the one of my throttle cables is bad, as well as them being a little short for my liking, so I'm just gonna make my own with the kit to get exactly what I want!
 

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Oiler Boilereerer...er(s)
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Discussion Starter · #20 ·
I dismounted the front tire using a vice, some zip ties and rebar wire. Started stripping the rim and spare tank. I'm kind thinking about polishing the wheels now...













 
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