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  1. #1
    Junior Member NSW
    Join Date
    Mar 2019
    Location
    Central Coast NSW
    Posts
    21

    Complete rebuild, advice needed

    Hello everyone, Nick here.

    So Ive decided to start looking for an 1100 kat and go to town on it.
    I have one in mind selling for 4k, runs, no noise or smoke, however its definitely seen better days.

    First question of many, engine rebuild, how far can I go and be reliable? I see 1068 seems common, however whats involved in say 1268?
    I don't mind if oil chambers need doing, resleeving etc etc
    This wont be a daily ride, basically a trophy to ride sporadically, I'll be looking at complete shock/forks etc so will be a major build.
    Still want it to idle at a set of traffic lights though.

    I'm based in NSW, so if anyone knows a reliable and knowledgeable mechanic that would be greatly appreciated.

    Thanks in advance,

    Nick

  2. #2
    Nick,
    Is that the blue one for sale at the moment?

    1170 is as big as you should go on standard barrels. Anything above that is a resleeve. Then I think in the 1300's you start to risk oil leaks as the sleeves can start to poke through the fins without an aftermarket barrel.
    There's guys on here with 1360's, 14- something and even maybe a 1500cc.
    Mine's 1260 and dialled for torque. Tons of grunt, still revs and idles perfectly.

    Mine also has upgraded suspension which I'm in the process of upgrading again.

    The sky is the limit.
    Boogieman (NBT, NSRL, ATMUPN, ROK)
    I wish I had as many cc's as posts!

  3. #3
    Senior Member QLD
    Join Date
    Oct 2014
    Location
    Keperra, Queensland
    Posts
    3,267
    Hey Nick, welcome! That one looks like a good relatively cheap starting point for a project (just going by the pic's anyway) and would definitely be a good place to start.

    I've not gone anything other than stock with my project so can't comment too much there but without the personal experience I'd definitely do a +1 to Ben's comment above.

    Not sure how well you know Kats, but heaps of stuff is still available brand new and the dealer we can highly recommend is Mick Hone down in Melbourne. You'll likely find the cost of postage on top of his prices still has a cheaper end result for the parts, but more importantly they know Kats and will give you great service.

    Starting off with a nearly complete Kat is great way to go too, don't do what I did and start with a bare frame and start acquiring bits along the way.

    Good luck!
    1984 Katana 7/11 - done at last!

    1982 GS450E - not quite stock

  4. #4
    Junior Member NSW
    Join Date
    Mar 2019
    Location
    Central Coast NSW
    Posts
    21
    Thanks for reply guys.
    I really want to get motor right, Boogieman, what else did you do for 1260?, crank etc? Gearbox?
    Knowing the whole process is always better, can this be done without having a workshop do everything?
    First place I rang quoted around $5k for motor, gearbox etc. Im pretty cluey at mechanical work.
    Ideally I'd like to go as big as possible without sacrificing rideability and having to strip motor every other year.

  5. #5
    Senior Member NSW Nick Kakasiouris's Avatar
    Join Date
    Oct 2014
    Location
    Kings Langley N.S.W. Australia
    Posts
    1,597
    Quote Originally Posted by nickstyl View Post
    Hello everyone, Nick here.

    So Ive decided to start looking for an 1100 kat and go to town on it.
    I have one in mind selling for 4k, runs, no noise or smoke, however its definitely seen better days.

    First question of many, engine rebuild, how far can I go and be reliable? I see 1068 seems common, however whats involved in say 1268?
    I don't mind if oil chambers need doing, resleeving etc etc
    This wont be a daily ride, basically a trophy to ride sporadically, I'll be looking at complete shock/forks etc so will be a major build.
    Still want it to idle at a set of traffic lights though.

    I'm based in NSW, so if anyone knows a reliable and knowledgeable mechanic that would be greatly appreciated.

    Thanks in advance,

    Nick
    Hi Nick, I use Old Gold Motorcycles at Londonderry N.S.W. they are near Windsor N.S.W. Ring up and ask for Steve and they will advise you.
    Nick
    You always meet a better class of people who ride and enjoy Motorcycling

  6. #6
    Junior Member NSW
    Join Date
    Mar 2019
    Location
    Central Coast NSW
    Posts
    21
    Thanks Nick,

    Bike is mine, just payed deposit and rest will be payed when shop emails clear title papers which he has.
    Woo hoo, let the fun begin.

  7. #7
    Congratulations! Buying a motorcycle is a thrill of pleasure! To wait for the first ride while being excited. Takahiro

  8. #8
    Senior Member QLD
    Join Date
    Oct 2014
    Location
    Keperra, Queensland
    Posts
    3,267
    Nice Nick!

    As for DIY stuff, yep, the only things I couldn't do for myself so far are true the crankshaft, press second gear back on after replacing fifth, and then welding second also. I did the rest of the motor build myself, although I've got the loan of a head as mine is buggered and needs rebuilding which will be a next year job, and I'll likely pay the guy who did my crank to rebuild it also.

    If you need to do things like re-sleeve and/or bore, unless you have the equipment you're going to have to go pro. Probably stating the obvious there but worth a mention.
    1984 Katana 7/11 - done at last!

    1982 GS450E - not quite stock

  9. #9
    Quote Originally Posted by nickstyl View Post
    Thanks for reply guys.
    I really want to get motor right, Boogieman, what else did you do for 1260?, crank etc? Gearbox?
    Knowing the whole process is always better, can this be done without having a workshop do everything?
    First place I rang quoted around $5k for motor, gearbox etc. Im pretty cluey at mechanical work.
    Ideally I'd like to go as big as possible without sacrificing rideability and having to strip motor every other year.
    Nick,
    I kept it simple and reliable which paid off.
    I did the rebuild myself but I am a mechanic, however; there're enough guys on here that aren't mechanics and have built their own bikes with great success too.
    Mine is 1260cc, APE slotted cam sprockets on standard cams dialled in for torque, welded 2nd gear, GSX750F 36mm CV carbs and Tingate exhaust.
    A big engine will increase rideability. Big cams, head work and carbs will give you impressive dyno numbers but will sacrifice rideability. So if you have the means, go big CC and dial it in for torque.
    As for frame, my suspension and brakes are a mix of ZX10, ZZR1100, R1, Hayabusa & GSXR600. This will soon become a mix of GSXR600/ 1100, SV1000 & Bandit (it kills me to have non-Suzuki parts on it).
    Boogieman (NBT, NSRL, ATMUPN, ROK)
    I wish I had as many cc's as posts!

  10. #10
    Thats a nice and simple engine. Cant beat it for a daily ride.

    Nige

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