Our unit keeps the upper cowl as-is and is headlight inspection-compliant.
Let’s tackle the remaining work bit by bit.
We’ll cover the inside of the cowl with metal-edged trim.
Suzuki 94631-44110 I’ve linked it, but it’s ¥2,550 (separate).
Please don’t use trim with double-sided tape on the inside.
Even indoors it’s questionable, but outdoors on a motorcycle it simply won’t hold up.
Plan to make the Inazuma snappier.
We’re shortening the final drive: 15T to 14T. Street riding felt significantly better.
The chain and sprockets were replaced last time, so we’re just swapping the lock washers.
Replace them every time and bend at least two spots for peace of mind.
Oil is seeping quite a bit from the shift shaft, so we’ll replace it at the same time.
This might be a bit tough to work on at home.
If you accidentally push this shaft after removing the snap ring, it’ll go flying.
If the bird’s-foot ratchet comes loose, next thing you know you’re removing the clutch cover—straight down the road to hell.
Removal isn’t a big deal (if you have the tools).
Avoid the method of tapping into the oil seal.
Success rate is surprisingly low, and if the seal gets stuck, you’ll make things worse.
Take a junk minus screwdriver, heat it, bend it, file it smooth, thread-cut an M6 boss, weld it on, and pull it out with a slide hammer.
As I wrote that, I realized I can’t make this at home either—which means customers can’t do it.
Connect it, tap it straight as much as possible, and just pull it out.
Even if you do it 100,000 times, it should work.
We always keep this oil seal in stock.
We pack fluorine grease inside the lip before assembly.
As for pressing in the oil seal, it basically goes in by hand.
If you have to tap it in, both parts aren’t in good condition.
This shaft area rusts easily, so we apply thread compound for rust prevention.
This grease sticks around stubbornly, so it’s great for this kind of application too.
We ordered NBR rubber sheet from Monotaro.
We punched the holes and finished the edges with a 15R radius.
This alone might really bump up the quality feel.
The Inazuma 1200 originally has switch wiring inside the headlight.
Converting to a Katana means relocating it—either under the tank or in the headlight.
I prefer the headlight route to avoid putting stress on things.
Raybric + NOVSIGHT LED bulb—it’s incredible.
Even with our old-generation light source tester, we’re getting 60,000 candela.
In reality, it’s probably putting out over 70,000… what a time to be alive.
The LED bulbs sold a few years ago were pretty rough, so upgrading is definitely better.
