Everlasting Race Kat Project

[Pedda]

In May 2009 I used my road legal Katana in a 3 hours classic endurance race, which only lasted 2h 55min for me. After that crash, I decided that I'd need a pure race Kat so that I wouldn't have to risk my road bike any more.
So here's the starting point of my project.

[bobster]

Ah .........wilcommen Pedda!

[Pedda]

Hi Bobster,
I feel it's about time to make this forum a bit more vivid, ya know...

So here it goes on.



I already had an old 1135 EFE, which had to donor the engine for my project.

The engine had about 70.000 km on the clocks and the first oversized pistons in since 500 km.
But in the end I put this engine on the shelf and started to build up a new one. I mate of mine swapped me a nearly complete EFE engine for a Bandit oil cooler.

Plans for the engine are:
head porting
1230 ccm Arias pistons C.R. 10.5:1
Vance & Hines #168 camshafts .340” lift 240 degrees duration
Adjustable cam sprockets
Tsubaki hd cam chain
Vance & Hines hd valve springs
Spark plugs: NGK Gold Palladium D8EV
V & H 5 degrees ignition advancer
Mikuni RS38 flatslide carburettors
K&N RU-0981 oval single pod filters (also on stock: 50mm velocity stacks)
Oil pump gear conversion to GSX705 for higher oil flow
Setrab oil cooler

[Pedda]

Borrowed a decent engine stand to work with...

When I took the engine apart I noticed this:

A snapped crankshaft bearing support! Referring to the title of this thread, you may now guess why I called it that way - project starts taking more time and getting more expensive...


Had to get me some new casings and on with the build...

[Pedda]

Did something special to the upper casing and the barrel:

Here's the corresponding areas in the cases:

The reason for this is: avoid pump losses, effervescence of the oil and let the engine rev up much easier.
Late K-Gixxers use this and a guy I know who's part of our local old school race scene and builds up engines for a living adapted this technique on the aircooled lumps and gained noteworthy effects by that modification.

[Pedda]

Assembly of the barrels. Not too easy with only two hands. So called my mates and promised to have some cold beer, which I always do...

[Pedda]

Oil pump gear of a 7.5 Katana engine, which I have kicking about...

Gives higher oil flow by different ratio.
1100 ccm engines have 33 : 34 teeth
750 ccm engines have 29 : 38 teeth

Just a straight swap.

[Pedda]

When I worked on the clutch in the past, I always ended up this way:

Pressed some rags in between the hub and the basket. About time to become somehow more professional by making me a special tool:

Much easier that is!

[Pedda]

Talking about tools:

Another very handy one when you're working on camshaft timing:

Made by the same chap who borrowed me the workstand and does all the milling jobs for me.



Next: a positive stop tool to find the exact TDC, made of a spark plug and a threaded bar. Just dig out anything what is in the spark plug, cut a thread into it and done.

Here it is in position:

At the same time fixing my self made dial gauge support:

[Pedda]

The whole cam dial assy with degree wheel: