GSX1100S Inspection, Harness Replacement, Muffler Installation, FCC Clutch, Oil Change, and More

26 April 2023

Wait, now that I think about it, the “harness replacement” was on hold, wasn’t it…

The customer pointed it out and I just realized. . . . (*´ω｀*)

Well, for a Katana it should be fine. Don’t worry.

OHNO SPEED: Oono Speed
Hybrid Main Harness
GSX750 GSX1000S GSX1100

This was brought in by the customer.
It’s really helpful that they sell reproduction parts like this
for Katana users.

Oil-cooled bikes are pretty much nonexistent these days. . . .

The wiring diagram is large and color-coded for easy viewing

Comparing it side by side with the manual’s wiring diagram, as you can see
it’s “large and color-coded” making it extremely easy to read.

Mistakes will be greatly reduced.

Same with OEM harnesses.
Always do an inspection (´ー｀)

In this job, I only trust what I see with my own eyes, so I always compare and check.
Just look at the connector shape, number, and color one by one.

It takes 15-30 minutes at most.
“Wait, there are leftover parts—what are these?”
That never happens.

This harness
comes from the start with “optional power/ground laid out in parallel at two locations.” Plus, there’s another accessory power connector, which is really helpful.

Suzuki OEM turn signals can have loose connections when they’re old.
In those cases, I remake them with male and female sets to get them paired up properly.

Oono Speed Reproduction Starter Motor GSX750S, GSX1100S, GS1000, GSX1150, etc.

I checked the gear outer diameter and tooth count before installing it.

You can only clean certain areas when the starter motor is removed,
so make sure to clean those spots thoroughly.
*The usual no-touch approach is the best (´ー｀)

Starter Motor Harness, GSX750S, GSX1100S

It’s really helpful that you can get this stuff on Amazon, right?

The starter relay shape differs depending on the model year max( ；∀；)

This flag-type terminal with a hook is convenient, but it’s a hard-to-find connector.
Since I can’t make it work no matter what, I’ll modify it and change the layout.

So I had to compress it, crimp it, and bend it 90 degrees.

The fuse box will be on the right, so it’ll come a bit further forward.

All GS/GSX models melt them. . . .
I’ll use 250-series connectors instead.

For now, the harness layout is complete.

Next, I’ll layout the accessories and other parts.
After that comes the final “wiring.”

Hopefully I can wrap it up this week (*´ω｀*)