Wiring instructions for 92 kat controls (pics)

[nastynate6695]

Ok so this might not ever happen to anybody else but just in case that it does im going to do a quick write up to walk you through it.

Problem-- I wanted to do a katana front end upgrade onthe gs. So i went online and found one.  Didnt have brake calipers so i had to go online and find those.  The calipers also came with the right side controls so i sold my gs one to someone in need.  Fast forward 3 months and i finally have my bike put back together.  Problem is that the 92 katana control plug does not fit with the 96 gs plug.

Before we get started let me inform you that although a large cluster of wires my look scarey and overwhelming it is actually really simple and easy as long as you are patient and pay attention.

Things you will need (or at least things i used during this project) 

1. One six pack of the greatest beer in the world (Yuengling)
2. A Soldering kit
3. 3M electrical tape ( dont use the bargain bin stuff its not the same)
4. Wire cutters
5. Dremel tool
6. Shrink Tubing
7.  Heat gun or lighter

Start with a nice cold beer.



Now plug in your soldering gun.  This will give it a chance to warm up while we go onto the next step.



Now i took out my trusty dremel tool with the cut off wheel attached to it for this next step. The reason i did this was so that i would have a solid surface to solder against.  Take the dremel and cut around the wiring connector that belongs to the gs.  When done you should be able to peel the plastic away and have all the wires free with a flat metal tip attached.



If you dont feel like doing this snipping it right after the plug with wire cutters and then stripping the ends is perfectly fine also.

Now cut the wires that run to the plug for the throttle control assembly.  Strip the ends of those back about ¼ of an inch so that the clean copper wiring has enough room to be folded around its counterpart from the wiring harness.

Everything should be ready to go. But before we start here are a few things to keep in mind. 

1.   Make sure that you slide the shrink tube on first before you connect the wires.  It's a little hard to get it on after the wires are connected.
2.   Make sure to test the wire connections before and after you solder just to make sure that everything is working properly.
3.   When connecting the wires together I ran it through the small hole in the connector, pulled part of the wire tip through, than folded the connector part over to hold it in place.
4.   When soldering make sure you tip is clean.  This will ensure the maximum amount of heat transfer.
5.   When soldering make sure you heat the metal not the solder.  When the metal or wires are hot enough the solder should just melt and coat it.



Ok now that that's out of the way here is the wire sync up.

Start with the brake sensor

From controls          From wiring harness

Solid black       to   Black with white
Black with line    to   Orange with black dashes

Kill switch and starter

Orange with black line   to    Orange with blue line
Orange with white line   to   Orange with white line

Orange with Black dashes to Yellow with white line (also include a gray wire in with this group) 

Notice that you have two Orange wires with Black dashes..Don't worry about these they are power wires and it doesn't matter which one you use.  They are larger then the other wires I believe 18 gauge instead of 20. 



Once you have all this soldered up and everything still works like it should go ahead and heat up the shrink tube with a lighter or heat gun.  This will shrink the tubing effectively sealing it from the outside elements.  Because I changed out my headlight along with the works I had to electrical tape everything up in a bundle and hide it behind the headlamp.



If you don't have a soldering gun or don't want to take the time to do it.  You can get away with just cutting and stripping the wires then twisting them together and taping them to seal and protect. Because my bike is outside uncovered a lot and I live next to the beach I didn't want to leave anything to chance.