1982 GSX1000 Build thread "Old School Suzuki" The Predecessor - GSXR.com
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post #1 of 56 (permalink) Old 09-15-2017, 10:08 PM Thread Starter
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1982 GSX1000 Build thread "Old School Suzuki" The Predecessor

Just thought I'd make a suitable thread for the coming build. Instead of a "looking for" thread.
I did finally manage to find the 1200 Bandit Motor conversion motor mounts for the Katana.
I went from the US to Japan to the Netherlands at the final search.
Pepijn Quist at Quist-racing.com had everything I needed.
Stainless motor mount kit and the billet exhaust spacer kits to make the exhaust right. 200.00 from the Netherlands.

I also managed to find replica brand new gauges(buy later expensive) So I can pull the 85 mph original gauges and replace with the 160 mph aftermarkets. As well as save this motor with 7805 original miles.

All original parts will be packaged and stored for its revival at a much later date.

Pics of the Original ride first (even though they were previously posted,some of them)

Now pics previous owner took since I'm waiting on delivery










More stuff to come.
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Last edited by Racerxxxgsxr1000; 09-16-2017 at 04:33 PM.
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post #2 of 56 (permalink) Old 09-16-2017, 11:15 AM
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And so it begins!

That bike is cleaner than it was new/showroom!

Nice search on the motor mounts!

Now you're going to have a GSX 11-12!
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post #3 of 56 (permalink) Old 09-16-2017, 04:17 PM Thread Starter
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I'm going to build the entire suspension front and rear and brakes first before motor swap.
I credit Rob Wilton @ Suzuki-Katana.com for much information

Parts acquired already:
1993 GSXR750 front forks, triple trees and front axle
1993 GSXR750 front wheel complete
1994 rear wheel (same as 93)
Rubber dampers for rear wheel
1993 four piston Nissin calipers with good pads.
Have good 2 trackday old pull offs Bridgestone RS10's 120/180-17's

Parts on order
Front and rear stainless wave rotors black inserts
Bandit 1200 motor conversion mounts and exhaust extenders.
RFY piggyback shocks built by Chris Livengood
(they are disassembled, cleaned, deburred, new oil, new spring and nitrogen filled)
They are overseas copies of the Ohlins which originally come air charged. Clevis ends will be added by Chris


Parts yet to aquire
Stock gearing was 15/42 630 chain had final ratio of 2.80
Offset 5/8 530 front sprocket 17T
Rear 530 48T (equals 2.82 final ratio compared to 630 stock)
Rear caliper and bracket
Chain 530 o-ring
New front/rr wheel bearings
New steering head bearings
Silver GSXR front fender(or paint with factory color match)
Valve stems
Titanium disc bolts front/rr

Work to perform first
strip wheels and calipers take to powder coater.
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Last edited by Racerxxxgsxr1000; 09-16-2017 at 05:54 PM.
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post #4 of 56 (permalink) Old 09-16-2017, 06:58 PM
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On a nostalgic note.

At the time when the first 1100 Katana came to Australia I was an apprentice working in a dealership that sold cars and also Suzuki bikes.

I owned a KL250 that I rode on the road and had owned a few other old dirt bikes, I had never ridden a road bike, and claimed to myself that I would only ever ride dirt and that I never wanted to go fast.

The owners son got an 1100 and I did the first service on it at 1000km.

As you do i had to test ride it, changed into top gear at 200kmh and was instantly sold on going fast on bikes.

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post #5 of 56 (permalink) Old 09-17-2017, 05:59 PM
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Sweet Sub'd this thread immediately.
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post #6 of 56 (permalink) Old 09-17-2017, 08:17 PM Thread Starter
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Thanks Tin!

Ok today took a little while, still using one arm for a while longer, its been 1 month and 3 days since my surgery.
So here's the job foreman that made sure I worked safe


Ok, blew pistons loose in calipers (pull pads slide 10mm wrench in between to get them started) then took bolts out of calipers and used my piston removal tool. Calipers are ready for black powder coat



Rear wheel only had bearings and valve stem, so I knocked them out and cut out stem.
Front had a tire on it, discs and bearings. So I stripped it and made darn sure both wheels were straight first

Decided, I'm going to drop the wheels and top triple tree at Atlas in Houston going POLISHED ALUMINUM
Bike will be back/silver and chrome look and chrome shield


Got physical therapy tomorrow, but might drop them off Tuesday.
Bike should be here tues-wedn I'm pretty sure, he's gonna text me 24hrs out.

I've got a jumpstart on this project anyways.
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post #7 of 56 (permalink) Old 09-19-2017, 08:29 PM Thread Starter
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Well, haven't got my 24hr notice yet for bike delivery but I did get some more necessities coming.

Front 5/8 offset 530 17T sprocket
Rear Stealth 530 48T aluminum sprocket
93 GSXR steering head bearings
Swingarm bearings/spacers and end caps
EK 530 MVXZ o-ring chain
93 GSXR 750 fork seal kit


Drove into Houston this morning dropped off parts at Atlas plating
semi-gloss black powdercoat front calipers and bolts

Chrome upper steering stem

Polish front and rear wheels.

Should be done in about a week or so.

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I'll always keep on keeping on.

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post #8 of 56 (permalink) Old 09-21-2017, 03:01 PM Thread Starter
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Well, got carried away and bought a 1200 Bandit motor with 19K miles on it, saw his video of stock bike running before he pulled motor, sounded good. 495.00 plus shipping, way cheaper than GSXR motor lol

Found a 1200 Bandit new swingarm on ebay for 120.00, couldn't pass it up.
Ordered installation kit for it from Rob.
Comes with shock mounts, swingarm bearing spacers and sprocket.

I'll keep all the stock stuff and bearings for later.
Want to extend that Bandit swingarm, but the extensions are bolt on and 350.00, screw that.

I'll have my own machined and welded.
Only looking for about 3-4 inches over, help keep that from wheel planted.

Driver called, bike will be here Friday...tomorrow.
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post #9 of 56 (permalink) Old 09-22-2017, 05:44 AM
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Awesome thread. I'm excited to see this build.

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There's a lot more women to look at!-WB
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post #10 of 56 (permalink) Old 09-23-2017, 07:12 AM
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By now you realize I'm basically always confused,

but, do you have it yet?

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post #11 of 56 (permalink) Old 09-24-2017, 12:10 PM Thread Starter
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Quote:
Originally Posted by Todd_Sails View Post
By now you realize I'm basically always confused,

but, do you have it yet?
The guy bounces around while driving so he can pick up more stuff since he's nationwide.
Was supposed to be here Friday, didn't show, called Saturday he didn't answer, texted him, he didn't respond until last night by text message saying he got tied up in New Mexico, he'd be here Tuesday.
I didn't reply, the fucker already said Friday, and I waited around all day, then he ignored my texts.
I guess since he has an always changing schedule, he used to lying to people. That's ok, I'm gonna chew his ass when he gets here for lying and ignoring.

You just don't do people like that. I'm easy going, I understand if something changes, but communication is the key, don't leave people hanging like WTF.

I'm gonna rebuild my forks in the meantime and pickup wheels and parts hopefully Wedn or Thurs.

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I'll always keep on keeping on.

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post #12 of 56 (permalink) Old 09-24-2017, 01:00 PM
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Thanks kinda BS if ya ask me, I can't stand people that are like that. If I was you I'd charge him a late fee, like a $100 bucks a day that he's late

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post #13 of 56 (permalink) Old 09-24-2017, 07:44 PM
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The guy bounces around while driving so he can pick up more stuff since he's nationwide.
Was supposed to be here Friday, didn't show, called Saturday he didn't answer, texted him, he didn't respond until last night by text message saying he got tied up in New Mexico, he'd be here Tuesday.
I didn't reply, the fucker already said Friday, and I waited around all day, then he ignored my texts.
I guess since he has an always changing schedule, he used to lying to people. That's ok, I'm gonna chew his ass when he gets here for lying and ignoring.

You just don't do people like that. I'm easy going, I understand if something changes, but communication is the key, don't leave people hanging like WTF.

I'm gonna rebuild my forks in the meantime and pickup wheels and parts hopefully Wedn or Thurs.
Sorry bud.... he 'should' be there on Tuesday if traffic and customs are good. He just dropped off your scoot here in Montreal. In good conscience, I couldn't let you bastardize such a clean, low km specimen. I only had to offer him $200 worth of lap dances! (errr, not by me)

Don't worry though I replaced that crappy old '82 Katana 1000 with a MUCH newer 88 1100 so you're up in years and CCs
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post #14 of 56 (permalink) Old 09-24-2017, 10:28 PM Thread Starter
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[QUOTE=K61000;3615313] I only had to offer him $200 worth of lap dances! (errr, not by me)
QUOTE]
Firstly that would be like 400 lap dances .50C each
I bet you wore your pink G-string didn't you?

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post #15 of 56 (permalink) Old 09-27-2017, 05:15 PM Thread Starter
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Ok, bike is now in my garage. The fun will begin.
Hopefully pick up wheels tomorrow or Friday.
Just remembered I have to pickup some 50mm clip on bars, the stockers certainly wont work for GSXR front end lol.

Bikes a little dusty, no problem.


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I'll always keep on keeping on.

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post #16 of 56 (permalink) Old 09-28-2017, 05:43 AM
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Thing looks great man! Glad you found such a good one.
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post #17 of 56 (permalink) Old 09-30-2017, 11:36 PM
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Awesome, awesome bike. Easily one of my top 10 favorites. There are some killer customs based on that bike. Even bone stock it screams Cool.

Still have to read the rest of the thread. Had to stop when I got to the RFY shocks. From what I understand they were scooter shocks. Even rebuilt, their quality is marginal at best.

Bike deserves more!
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post #18 of 56 (permalink) Old 10-01-2017, 12:20 AM Thread Starter
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Awesome, awesome bike. Easily one of my top 10 favorites. There are some killer customs based on that bike. Even bone stock it screams Cool.

Still have to read the rest of the thread. Had to stop when I got to the RFY shocks. From what I understand they were scooter shocks. Even rebuilt, their quality is marginal at best.

Bike deserves more!
These are almost direct copies of the Ohlins, did my research and reviews.

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I'll always keep on keeping on.

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post #19 of 56 (permalink) Old 10-01-2017, 06:29 AM
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Having never personally rebuilt a pair of these shocks, it would be stupid of me to disagree.

I do know of one racer that modified these shocks for track use in a lighter bike (yamaha rd).

I think the mod list was a new lower clevis, spot facing and drilling for bleed screw to completely fill the shock and correct sprigs and shock oil. Maybe something about the seals, too. I cant recall.

With that, I understand they work decent. But the work involved brings it up to the price of other quality suspension.

Look forward to reading about your experiences.

Great looking bike!
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post #20 of 56 (permalink) Old 10-03-2017, 08:17 PM Thread Starter
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Drove to Houston in the rain 4 hr round trip got my parts I took to my guy
Polished aluminum, chrome on wheels flakes after rock chips and polished give a natural luster of the aluminum I like.
Rule of thumb, chrome where rocks wont hit, that rules out fork legs, wheels and swingarm in my opinion. I've seen it all before.




Chrome upper tree



Powder coated satin black calipers. Rebuilt tonight. Cleaned pistons, new seals, new bleeders with caps and new cross over seals. Also had the half bolts powder coated.



Waiting on titanium disc bolts, but I'll install bearings, stem, and mount tires tomorrow.
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Last edited by Racerxxxgsxr1000; 10-03-2017 at 08:22 PM.
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post #21 of 56 (permalink) Old 10-04-2017, 11:48 AM
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Dude, that is one sexy bike! love it!
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post #22 of 56 (permalink) Old 10-04-2017, 04:48 PM Thread Starter
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Thanks Valiant.

Tapped all holes, installed stem, mounted tires and loctited disc bolts. I haven't even put a final shine on them yet, I got plenty of time lol




Should be wide enough for the old ride.

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post #23 of 56 (permalink) Old 10-04-2017, 04:52 PM
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Those wheels on that bike are going to be sick.
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post #24 of 56 (permalink) Old 10-04-2017, 07:51 PM Thread Starter
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Those wheels on that bike are going to be sick.
I guess the next step is stripping the bike to the bare frame and swapping motors. But it'll take a little time to clean and paint a few engine covers that need it. Get that frame spotless and motor ready. My engine mount kit is being shipped this week. So I should have it by the time the motor is ready to go in.

I just had to put the wheels together, it was way too tempting lol
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post #25 of 56 (permalink) Old 10-05-2017, 04:05 AM
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Sweet... Subscribed!!!

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post #26 of 56 (permalink) Old 10-07-2017, 12:09 PM Thread Starter
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And so it begins. Put 1200 motor on lift needs cleaning pretty bad.
Pulled upper fairing ,seat, tail, exhaust then ran out of time.



Hope to have motor mounts next week. Gotta work like the next 4 12hr days, then one day off then another 4 12hr days, a day off and another 4. I'll be pretty busy unfortunately.

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I love you dad, you'll be greatly missed.
I'll always keep on keeping on.

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post #27 of 56 (permalink) Old 10-07-2017, 01:14 PM
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Originally Posted by Racerxxxgsxr1000 View Post
And so it begins. Put 1200 motor on lift needs cleaning pretty bad.
Pulled upper fairing ,seat, tail, exhaust then ran out of time.



Hope to have motor mounts next week. Gotta work like the next 4 12hr days, then one day off then another 4 12hr days, a day off and another 4. I'll be pretty busy unfortunately.
It sounds like a winter project anyway.
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post #28 of 56 (permalink) Old 10-08-2017, 08:28 PM
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I dont know if people have seen this website,

UNICORN JAPAN

Its a katana workshop.

If you have a look at the faceBook page "Unicorn World" they have a nice little Vid of bikes in the showroom.

I owned a 750 pop up headlight model.

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post #29 of 56 (permalink) Old 10-21-2017, 05:24 PM Thread Starter
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Finally found some time to work in the garage. Finished stripping bike and pulled motor.
The 1 1/2 armed man strikes again!



That motor has come out at some time or another, there was blue painters tape on the inner lower frame rail and a few scratches on rear section or motor area. I wish I hadn't seen that, now I want to powder coat the frame. I could use epoxy gray and do it myself, I'll have to think on that one.
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post #30 of 56 (permalink) Old 10-30-2017, 07:32 PM Thread Starter
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I dont know if people have seen this website,

UNICORN JAPAN

Its a katana workshop.

If you have a look at the faceBook page "Unicorn World" they have a nice little Vid of bikes in the showroom.

I owned a 750 pop up headlight model.
How are you man? I've been to that site, but they are extremely pricey for their parts.
The 750's are rare now too.

Until I can back on the track next year, it's just been Katana time.
I dropped the frame off for powder coating and a handful of parts with it.
Motor mount kit came in today, swingarm kit will be here Friday.
Just ordered stainless exhaust down pipes for Bandit, didn't buy complete system because I know the rear section probably wouldn't fit. I'll make my own rear section to fit.

Ordered 93 gsxr750 rear brake caliper assembly, engine sprocket cover with slave cylinder and spedo sensor.
Using 2002 Bandit wiring harness and ECU.
It will be a clean very unique build for sure. I'm all in at this point.

Buying a turbo kit in March.
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I'll always keep on keeping on.

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post #31 of 56 (permalink) Old 11-01-2017, 06:40 AM
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Wow, I have to admit that I have never seen one of these before. Subscribed, can't wait to see the final outcome!

On another note, your dog is awesome and it's inspiring that you're doing all this work without the use of one arm....
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you have in your hands one of the nicest looking bikes I've ever seen. Great work! That is a beautiful bike.

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post #32 of 56 (permalink) Old 11-01-2017, 03:22 PM
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It's going to be awesome, and I'm really impressed.

But, that Low miles 1100, has evidence of the motor already has been pulled?
That's the motor your saving? Have you heard it run?

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post #33 of 56 (permalink) Old 11-01-2017, 05:22 PM Thread Starter
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It's going to be awesome, and I'm really impressed.

But, that Low miles 1100, has evidence of the motor already has been pulled?
That's the motor your saving? Have you heard it run?
I rode the bike, motor is fine. I think he was doing some restoring is what I'm thinking. I see a lot of people who need better skills lol
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post #34 of 56 (permalink) Old 11-02-2017, 11:54 AM
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I rode the bike, motor is fine. I think he was doing some restoring is what I'm thinking. I see a lot of people who need better skills lol
Awesome- Carry on

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post #35 of 56 (permalink) Old 11-06-2017, 03:50 PM Thread Starter
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Frame should be done by this weekend. Metallic Silver. Having sidestand, electrical side plate, battery box and grab rail on side done black coat.

Almost finished cleaning Bandit motor. I have all this install parts minus oil cooler, but I ordered it today for $31.00 with hoses.
Ordered stainless bolts for alternator and starter and sprocket cover(upgraded to hydraulic clutch now). OEM was $14.00 for those bolts. I got them all in stainless for $9.95.

Stainless motor mount kit is here as well as stainless Delvic header down tubes. I'll make my own muffler back from there to fit.

Once motor is in frame, things will start moving pretty quickly since I have most parts waiting.

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I love you dad, you'll be greatly missed.
I'll always keep on keeping on.

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post #36 of 56 (permalink) Old 11-16-2017, 07:29 PM Thread Starter
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Got frame back and started installing engine bolts. Definitely not n easy swap. Have to make spacers to fit width of Bandit motor, still need to get more stainless bolts and align the motor. But I'll get it close, install front end and get swingarm built. Ordered swingarm extensions from Exoticycles today, they'll ship Monday.

Might stand up frame with motor tomorrow night if I have energy after another 12hr work day.







Have to paint a couple engine covers also that the boneyard guys scratched up.
But most all of motor has been degreased and cleaned, looks pretty good.
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I'll always keep on keeping on.

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post #37 of 56 (permalink) Old 11-30-2017, 07:14 PM Thread Starter
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Motor is now bolted in firmly after getting right bolts and cutting my own spacers to length, that was a job. Ordered aluminum stock cut, then brush finish and clear coat them.



Fork bushings should be here tomorrow, already have forks torn down , cleaned and ready to go. With any luck I'll have front end back on tomorrow and ready for front wheel, installed extensions for rear swing arm, this monday it goes to the welder.


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My father left this Earth for Heaven 5/22/18.
I love you dad, you'll be greatly missed.
I'll always keep on keeping on.

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Last edited by Racerxxxgsxr1000; 11-30-2017 at 07:16 PM.
Racerxxxgsxr1000 is offline  
post #38 of 56 (permalink) Old 12-01-2017, 05:04 PM
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Just beautiful so far. Great work, it'll be a new bike when you're done. I curious how those shocks will work, as I need a set for my beater '86 Fazer. The only thing holding me up is their short travel, only 68mm. The Fazer is already short of rear wheel travel. I did notice on the guys web site that he can increase the travel with short top out springs. Might be the way for me to go. Or maybe I should just ship my bike to you, and get it done right! Can't wait to see your bike finished.
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post #39 of 56 (permalink) Old 12-01-2017, 08:43 PM Thread Starter
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Quote:
Originally Posted by bobl View Post
Just beautiful so far. Great work, it'll be a new bike when you're done. I curious how those shocks will work, as I need a set for my beater '86 Fazer. The only thing holding me up is their short travel, only 68mm. The Fazer is already short of rear wheel travel. I did notice on the guys web site that he can increase the travel with short top out springs. Might be the way for me to go. Or maybe I should just ship my bike to you, and get it done right! Can't wait to see your bike finished.
lol thanks Bobl. The Fazer is a cool bike, Genesis motor and all. They were pretty quick. I always saw them as a mix between sport and cruise. It's actually hard to find 93 gsxr 750 forks that arent destroyed. They are pretty old now. With sportbike forks that old now, you have to totally rebuild them and hope all internals are good.
The FZR1000 front end is a bolt on swap for your bike, same steering head size and Vmax rear shocks are a little taller and bolt right on as well. If stock front end, I'd go with Progressive front springs, 10wt oil and no air in forks. My buddy back in the day used to be a wheelie king on his Fazer.

My father left this Earth for Heaven 5/22/18.
I love you dad, you'll be greatly missed.
I'll always keep on keeping on.

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Racerxxxgsxr1000 is offline  
post #40 of 56 (permalink) Old 12-02-2017, 10:57 AM
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Kudos to you Racerxxx for your attention to detail and dedication. The rebuild looks great.
You probably have thirty hours in your day, or you are minus a Mrs Racerxxx and junior racers because I have my crashed GSXR that is waiting for me to get it back in shape and I find it very hard to allocate enough time to get any real progress done with my three kids and the Mrs in tow.
Congratulations, Iím jealous!


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