Inazuma 1200 GSF1200 Conversion! Unleash the True Oil-Cooled Power with BST36 Carburetor Swap & AS Uotani SP2

It’s a hassle, but there’s something exciting about using a carburetor with an air cleaner box, right?
We’re working on converting the Inazuma 1200 to GSF1200 spec (stock).
Since we’ve done this before, I’m reading through my old blog posts to refresh my memory…

That’s right, that’s right.
By the way, we’re scheduled to open from 1/7 (Wednesday). The factory is next door, so it’s easy and fun!
Here’s to another year of hard work and good vibes.

Enlarging the air cleaner box to the correct position

You can’t just wing it with machining work…
If you prepare positioning guides first, you can work endlessly.

We enlarged the holes like this.
We pry it out while minimizing metal shavings.

Heat removes it like this.
The issue is that air cleaner boxes deform slightly over time, so you need to be careful.

Heat a grooving cutter (without power) on the stove and pry it out in one go.
Smoothing it with your finger right after prying saves time.

Inazuma 1200 → GSF1200 conversion progressing.

It can be installed just like the original.
We’ll use GSF1200 throttle and choke cables.

We’re using NGK power cables with the Uotani full power kit.

The plug hole cover unique to oil-cooled engines is a non-removable part.
This part has gotten ridiculously expensive… I can’t really afford it.

Don’t force it into this hole…
Unexpected issues could arise…

The hole position is tricky and hard to enlarge, that’s real.
Using a 20φ packing punch clamped in a vise removes it cleanly.

Slimming down the packing punch slightly on the lathe will make it work even better.

Setup is good to go like this.

The Uotani main unit bracket is titanium

It doesn’t have to be titanium, but…
I had some lying around unused, so I’m putting it to work.

We’re mounting it almost exactly where the stock unit goes.

Making a REV mounting bracket.

We decided to mount it like this.
It’s on the right side when you’re sitting on it!

I did various reverse lookups…
I’m checking parts lists for newer models with 12φ breather hoses.

Probably the GSX-R1000R at around 12φ for 800 yen, so I’ll order two and lay them out.

Now that the machining setup is done, I’ll keep moving forward with the rest of the work.
We’re scheduled to open from Wednesday.