Katana Owners Club U.K.

Hi all,

Just over a week ago, my other half purchased a '81 650GX.

It's basically intact, and running, and has been the victim of countless years of paint abuse (layer upon layer on the frame, engine & carbs sprayed with a rattle can, and the tank sprayed matt black over the Suzuki decals even!), so it's going down to the bare metal, and is going to be done properly.

I'm not sure what to look out for on these machines... the mileage is unknown, and there was a reasonable amount of oil in the inlet ports and airbox from the breather pipe, so I'm assuming the engine has covered more than a few miles. Are they prone to piston ring wear or are they fairly bomb proof? I know that question is kind of like how long is a piece of string, but a mate bought a Honda CB-650 (SOHC) in the summer with 39k on the clock, and has ended up shelling out for new rings and valves, due to compression circa 100psi. I havent got a compression tester!

I have noticed that it started "on the button" from cold with choke, and revved cleanly enough, but when I went to ride it into the shed, it seemed to really struggle and I had to give it lots of gas and slip the clutch. And it won't tickover without the choke. Hopefully it's the carbs that need setting up. Any further ideas?

Sorry for boring you!

James

Thanks Blix...

On a limited budget here, and had planned to do the engine at the end of this year.... If we can get away without it, then here's hoping!

Hi James, welcome to the club. Yeah, lots of 650 peeps on here. Even those who dont have one have prob had one before I dont know much about anything really but good luck and if your working on a budget(like me) than i suggest you brush up your ebay skills, as sometimes its cheaper just to replace something then to fix it. Not being funny but if you think the engine is poobar, than rather then spend a few pound too much on it to get it fixed...just try and pick up another engine someone on here prob has one in his shed anyway !!! no names- you know who you are.

Strip it down and get a oily rag on it

Pete

Hi and welcome aboard.
Personally I'd dump the old fuel in the tank and give the carbs a clean then see how it goes from there.
Rather than strip the carbs completely you might get away with taking them off, take the float bowls off and give everything a good old spray with carb cleaner.
A bit lazy I know but it's worked for me in the past.
Might also be worth checking the fuel tap filter isn't full of gunge.
Sorry if this is all a bit obvious.
Never had one myself, but those who have on here say they're crackin bikes.
Best of luck.

650's go forever. they all smoke a little from 30'000miles on as the valve guides wear, if you don't do them they will not get much worse though mine struggled a bit after 250,000 miles.
The first thing to do is disconnect the choke cable... Daft *onda design! JUST PULL THE BAR OUT WITH FINGERS.
You symptons are synoymous with the choke looking like it's off but number 2 cyl is slightly on .
Check charging with lights on and don't turn them off and reg rec will last forever.
Oh and welcome aboard where are you based.

Based in West Norfolk... Downham Market!

Have also found a load of Silicone RTV squirted in the side of the cooling fins, to disguise a weepy head gasket... Will clean it up, and see how it goes! My mate had a 550 that used to do that, and every now and again he used to re torque the head nuts, and it would pack up.

Will leave the engine alone for the time being then (Saved the cost of a gasket set!), and see what happens.

Not many other issues, usual seat bottom plate corrosion, non standard bars fitted, front brake sliding pins missing one side. Swing arm is just starting to look rough round the driveshaft tube at the bottom, all of the bearings etc seem ok. Non standard chromed springs, and calipers painted red (sorry for mentioning red!). Did the Katana have air forks? Looking at the manual for the GS-650G, they did... but ours hasn't! Going to need fork seals & oil too.

Here is a vid of it running in "as bought" condition: http://www.youtube.com/watch?v=OygwLZOSmHU" onclick="window.open(this.href);return false;

Cheers,

J

Air forks, No but they are adjustable under the black cap.

We have 1 seat base left but I reckon the last 650 owners want's that , so I can get some more done if needed. If I can find the company in the maze of units in the mill where they were.

As for head gasket leaking most likely the front of the camchain tunnel weeping and running back through the fins. and or rocker leaking and coming out of water drain holes in the head.

Actually, somebody did mention cam chain tunnel worn through... but it doesn't appear to have.

Will have a better idea once we get the engine out, degreased and the paint stripped off etc. It's nearly ready to come out.

The oil cooler pipes are looking very ropey (the hose connectors at the oil cooler end) - the crimps have totally rotted to oblivion. Would a hydraulic supplier such as Pirtek be able to remake the ends do you reckon?

Ta

The leak is usually from the 10mm bolt fitted from the underneath at front of head , it'll be snapped off!
the GZ model had an extra bolt on the cam cover at camchain tunnel to sort out the leak.
As for hoses maybe , but I tried once to get a hose company to do some and they struggled because the pressure of hyd and oil are different so the fittings are different.
But it's goota be worth a go. Peugeot Serville paint in rattle can) for the calipers by the way.

added this
http://www.ebay.co.uk/itm/83-Suzuki-GS- ... 2c65fedc73" onclick="window.open(this.href);return false;

Thanks for that... will know more once we get the lump out. Best i get the drill and helicoil kit out if it has snapped!

There is an agricultural supplies place locally that makes up hoses... will drop in with them and see if they can do anything with them.

Thanks for the colour info!

Next question is the rear brake pedal spindle... it seems to flop about slightly! Was there a nylon bush or needle bearings that have disintegrated? Or do I have to hack off and weld on a new bit of tube onto the frame?

The joys of bike restoration.... not!

Thanks