New addition to the garage - now with bonus MOT

[Casper]

You remember the Katana forum. Lots of bits. Just a bit late with this as a guy wants rid of a 650 kat. Its on eBay now.



https://www.ebay.co.uk/itm/Suzuki-GS650-Katana-complete-bike-for-spares-/140888971881?

Keep what you need and brake the rest. I not long stuck newer switchgear on my 80's Kwak. Easy job if you have the wire diagram that the bike's new switches are coming from. Infact the L/H side was the same wiring, only had the right to do

Just incase you forgot

https://www.katanaownersclub.co.uk/forum/index.php

Also look at GSX switchgear. GSXEF, ES, EFE. They should be very close to the GS with minimum or no wire swaping.

[nowhere.elysium]

I'm vaguely tempted by the Kat, but I'm not sure I've got enough room in my garage. it's a bit packed at the moment

Also, I'm pretty certain that it's not the switchgear that's at fault: I've striped it, cleaned it, and checked it for continuity, and it's fine, according to every test I can think of.

Personally, I'm wondering if there's just a break in the loom somewhere, that's gotten worse with riding due to vibrations or something. Either way, there's a replacement loom on its way, and I'll use that to help me diagnose the problem areas.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[nowhere.elysium]

The wiring loom arrived yesterday. It's from a G, not a GT, so there's likely to be a few differences, but nothing I can't get around. As it is, I'm only interested in using it for troubleshooting purposes for now.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[Fizzer Thou]

If it is an intermittant fault it is quite likely to be around the headstock area.I had such a problem on an old CB550F a few years ago and ended up chasing the fault by connecting a multimeter at each end of the relevant wire and flexing/bending the loom in any suspicious areas.It ended up being a faulty connection where Honda had twisted some common feed wires together and the solder holding the wires together had corroded.

If you still have my number you know where to find me if you should need any help.
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Just talk bikes.What else is there?

Always have a 'Plan B'

[nowhere.elysium]

Fizzer, it looks like I may be about to take you up on that offer. I've got the loom off the bike now, and while it appears to be in good nick, none of the wiring diagrams I have seem to bear much relevance to what's sat in front of me right now. I'm reticent to cut away the tape that's binding the whole thing together, on account of the loom being marginally older than myself, and self amalgamating tape costing a shitload compared to regular electrical tape. Not to mention my complete lack of the stuff.

I'll report back when I've got a clearer idea as to what's happening next.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[nowhere.elysium]

So, one gutted loom later:
https://farm9.staticflickr.com/8363/8322854082_9679dbb88a_z.jpg

https://farm9.staticflickr.com/8358/8322853382_544ee36650_z.jpg

Not only was I greeted with a load of water falling out at me, I was presented with several taped spurs leading off from the loom, like the one pictured above. Suspiciously, I decided to unwrap it to check the state of the wires contained therein.
https://farm9.staticflickr.com/8501/8322853150_8a1f4fcbbc_z.jpg

Not so bad, thinks I. However, this turned out to be the best one. I'm not fond of crimps at the best of times, but discovering that there are ~12 waterlogged crimps that look like this:
https://farm9.staticflickr.com/8221/8322853538_2a51ba7236_z.jpg

Well, not best pleased doesn't even begin to cover it.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[nowhere.elysium]

Special mention goes to the retard who crimped this:
https://farm9.staticflickr.com/8504/8322096199_34d57ef739_z.jpg

Yes, that's two linked crimps, with at least six wires collated into two.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[MarJay]

I managed to get a pattern loom for my RD350, and even then it didn't quite match with the original, I had to re-crimp a load of the connectors as I didn't have both ends of some of them. (The OEM Yamaha ones are discontinued, so I just bought similar ones on ebay and crimped them both).

I'm really glad I did though as it has transformed the bike from a scary unreliable crate to a useful rideable bike.
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[stonesie]

I cant wait to get into the loom on my Triumph... It's got oriental writing on it and i'm hoping that's a good thing.






*I really hate electrics... Soon I will know your pain on this one

[Kickstart]

Hi

Given the wire colours and the types of crimp I would suggest that those are possibly original crimps from new. Just someone has stripped the loom back looking for a problem and then taped them up with insulation tape.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[nowhere.elysium]

[Kickstart]

Hi

Might have been done by the original dealers or one who serviced it.

The yellow tape is way too messily done for something which was mass produced.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[nowhere.elysium]

[bladerunner]

Just read the entire post! Hope you get the electrics sorted soon! I had the 650 kat version..picked up a doggy one with shot 2nd gear and shagged cams.....air box= effin nightmare so sympathy there. I fitted another motor to it I bought from a breakers and yes it also has a shot 2nd gear! One stupidly heavy engine and I mean steam engine type heavy? Jeez next bike I had was a slabby GSXR and I could carry that engine easily even tho it made 50% more power. I gave up on my kat after the shaft snapped so I guess it had had a rough life! Oh yes it has a rotted seat to.....I couldn't find one 15 years ago let alone now! Superb thread by the way
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Current bikes...cbr929, KDX200's, Rd125lc mk2, RGV250's

[nowhere.elysium]

[nowhere.elysium]

Well, I've wired in an alternate starter switch, and it works, although the battery has been drained to the point where it won't operate the starter relay, so I've had to put it on charge overnight.

Who knows, I might even be back on the road tomorrow.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[MarJay]

[nowhere.elysium]

Lo and behold, the beast lives once again. I was still having trouble with crap earthing points, so I think I've managed to sort as many of them out as possible. It genuinely wouldn't surprise me if that was the original issue with the stock starter button. Either way, I'm using my new alternative, which is sufficiently out of the way to deter opportunists, I hope.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[Howling Terror]

Show me your beast.
Show it to me now.













And well done.
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Diabolical homemade music Bandcamp and Soundcloud
Singer songwriter, Artist and allround good bloke Listen to Andrew Susan Johnston here
The Harry Turner Project

[Doovy]

Go Gerry, woo!
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Yamaha RXS 100 > Honda CD 250 > Honda Hornet 600 > Honda CBR 600RR > Yamaha RXS 100 > Kawasaki ZX6R J2 > Yamaha FZ1