Hello everyone! I have a 2001 Katana 600 n/a on the miles as I just bought it a few weeks ago. It was part of a storage unit auction where people don't pay their storage rent. I had to get new keys, ignition, helmet and tank locks. The battery that was in it was bad, so I replaced it. Now when I turn the key on, the headlamp comes on, the light above the headlights, but nothing else. I do not get dash lights or anything except the headlamp. I am assuming that because that light is on, the main fuses are good. I also checked them to be safe. I also checked all the connectors and they seem to be fine. There is, however, an extra connector that I have no idea what it is for. It is on the right side and comes from the main harness as the harness keeps going and plugs into the dash and such. There is also another small two pin connector down near the battery on the negative side that I do not know where it goes. On the other hand, there is a bolt there so it might be a ground wire. Any ideas?
A wiring diagram is a must...the loose connectors are probably for another country's DOT requirements. Makes sure all the fuses are tight and actually OK...a simple test bulb across the pins. Also check all the relays...pull them and then re-install them. And finally check the kill switch...make sure it is off and maybe cycle it a few times also any safety cut outs...side stand comes to mind....again cycle the switch a few times...these things tend to gum up over time and as this bike was in storage for a while it may be a simple case of a sticky switch.
Thanks for the tips! I have done all the ones you mentioned, save pull the kill switch. But would that really keep power from going to the dash cluster and such?
No not usually but you never know. I would also check the battery cables are fully secure and the starter motor/solenoid are getting power. You may want to double check the new ignition switch wiring...you definitely need a wiring diagram to do this. Also check the harness connection to the instrument cluster...not sure but there may be a separate fuse up there...try wiggling it to see if there is a broken wire within the harness....presumably this passes the steering stem and may have cracked or broken wires within it.
A quick google search gave several 01 Katana wiring diagrams...this is a simplified one that you may find useful...that is if the link works.