Katana Owners Club U.K.

Hi...hoping someone can help.
Almost finished a self rewire of my Kat...everything seems ok other than main lamp. Tracked it back to broken hi/low beam etc switch. Sorted out the problem (I think!) but stupidly having never taken the switch assembly apart, didn't take pictures first.
I have 2 springs which go somewhere but have no idea where (yellow dot). Also in pic (red dot) is a small spring in the little hole.
Feel stupid but hoping for help ...thanks

I believe those springs are captive behind those brass sliders?

Thanks...I have those two springs in place under the sliders, so something else. Cheers

Regarding the rewire, that seems like a big project. Can we still get a wiring harness for this thing? Or does after market make them. I plan on getting a modern ignition system, but was wondering for the rest of the running gear.

IIRC there's two springs that slot into the sliding part that make it return to center. It's truly a POS to work on and you can never get them fixed if they're broken.

Bikeazoid wrote: ↑

Tue Oct 13, 2020 7:06 pm

Regarding the rewire, that seems like a big project. Can we still get a wiring harness for this thing? Or does after market make them. I plan on getting a modern ignition system, but was wondering for the rest of the running gear.

Plenty of harnesses kicking about. GS1100E/ET/ES/EFE can be adapted. Biggest difference is the turn signal relay. What do you want to achieve with a different ignition system? The stock stuff is plenty for stock power. Dyna coils etc. only come into play with big bores and flat slides...

Thanks for replying, I thought converting it to a more modern setup would make it more consistent. At least that's what I got from this guy.

http://www.suzuki-katana.com/katana_wiring.html

I want to do a modest bore and 34 Mikuni flat slides also.

Thanks Blix, I thought the 1000 motor had stronger crank and rods. If I could find an 1150es motor I would. Also I'm in the US, I don't think anyone here cares about the Kat motors.

Why is the 1000 motor so sought after. I hear only the US got those, you guys got 1100's every year. Do you import our 1000 motors from the US?

I was wondering about the 36's I heard I would loose torque with them.

Also I read here somewhere that the US Kat 1000's were less collectable because we had crappy CV carbs and lame wheels.

Three times over the years I have had the turn/main/dip button fall off whilst I have been out riding. Perhaps I use the indicators too much??

Twice I replaced it with a genuine Suzuki assembly. After it came off the third time I managed to grab hold of the button and use it to make an improved metal slider part that goes in the switch. This has not come out (yet!).

I still have one original switch unit, without the button. I have partially stripped it and here is a photo of the inside. If you need me to take it apart further just let me know. I can also take higher resolution photos.

I'm not too sure about the location of the two black parts at the top. They fell out as I took the switch apart. I do know that the flimsy plastic part goes back in first, then the thicker part with the slots in it, but I'm not yet sure which way around they go.

David

Thanks David...that's a great help. Shows clearly where one of the springs goes I know how the two black bits of plastic fit...so just one more spring and a small ball bearing to go. It is a pain putting it back together but once I know how the last two bits fit will persevere till done
Cheers
Jerry