A rare GSX250S Katana.
The later-generation Katana models have various rationalized designs—it’s educational to see.
We’re planning to start with the outsourced work first since the inner tubes need re-plating, but…
The key cylinder has an anti-theft shear bolt that’s a bit of a pain.
Plus, we don’t have a 37mm jig, so I made one on the fly.
Make a stepped mandrel and clamp it, and you can easily get a flat surface.
Better workability and reliability.
Since the shear bolt doesn’t have a flat surface, a simple jig like this lets you center-punch it safely.
You can center it this easily, so it’s a breeze.
Gently with pliers… it won’t budge at all.
Even welding a rod to it… not a budge.
Finally got it off by welding a nut to it…. Things don’t go smoothly right at the start of the year, huh… It’s deep stuff…. ( ﾟДﾟ)
