{"id":42969,"date":"2019-09-08T15:21:10","date_gmt":"2019-09-08T06:21:10","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=42969"},"modified":"2026-09-24T13:45:14","modified_gmt":"2026-09-24T04:45:14","slug":"inazuma-1200-oil-cooled-katana-gsx1200s-main-harness-replacement","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20190908\/everyday-events\/inazuma-1200-oil-cooled-katana-gsx1200s-main-harness-replacement","title":{"rendered":"Inazuma 1200 Oil-cooled Katana GSX1200S Main Harness Replacement (Inazuma 400 Adapter) and Light Maintenance"},"content":{"rendered":"
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Inazuma 1200 oil-cooled Katana main harness replacement. It’s been several years since the 1200 harness was discontinued\u2026
At that time, the owner got a 400 harness thinking “well, if it’s a 400!” and we’re swapping it in.
Will it work? It’s Suzuki, so probably. Should be fine. But let’s check. Alright, let’s get to work. <\/figcaption><\/figure>\n\n\n\n\n\n\n\n
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We quickly removed the fairings. Bikes from this era have great serviceability, don’t they? (1999?) <\/figcaption><\/figure>\n\n\n\n
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Momentary freeze. How did the Inazuma go again???
The fuse box won’t come out = it’s the reverse pattern.
(Everything except the fuse runs through from under the air cleaner box.) <\/figcaption><\/figure>\n\n\n\n
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We stripped out the harness. Since we’re keeping a spare, we didn’t cut it carelessly.

Harness replacement has the image of being a hassle at first glance, but if you proceed carefully and neatly, it’s not really a pain.

Basically, manufacturers design things so they can be replaced. Don’t rush or panic.


There are times I really dislike it\u2014like when the harness is modified during removal and you have to cut it. When it comes to aftermarket parts, if you think not just about “installing” them but about “installing, functioning, looking good, and maintaining well,” you might actually get surprisingly good results.
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When removing the harness, try not to make it look like a tangled mess. The person working on it gets a bit queasy too, so if you remove it simply and in a way that looks good even if someone’s watching, the quality might improve. <\/figcaption><\/figure>\n\n\n\n
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That said, this Inazuma 1200 has limited space to hide wiring, so there’s quite a bit of extra work.
With aftermarket Watanabe ignitions and such, it’s good to install them without using the included accessories and in a way that’s convenient. <\/figcaption><\/figure>\n\n\n\n
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Every time we do this job, we compare old and new (400 on top, 1200 on bottom).
They’re pretty much twins\u2026 as expected from Suzuki. But we’re grateful. Result = basically OK (just a few differences). <\/figcaption><\/figure>\n\n\n\n
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Difference: presence or absence of TPS. We’ll add this. It just goes into the igniter and ground. <\/figcaption><\/figure>\n\n\n\n
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Neutral switch shape difference. <\/figcaption><\/figure>\n\n\n\n
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Probably the presence or absence of a fuel pump. <\/figcaption><\/figure>\n\n\n\n
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The 400 doesn’t have one. The rear brake switch wire comes out from a weird place. <\/figcaption><\/figure>\n\n\n\n
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Some extra wires present or absent.
Orange\/black\u2014on Suzuki this goes to the fuse-kill switch.
Black\/white (ground).
With these two wires, is it optional? <\/figcaption><\/figure>\n\n\n\n
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Oil-cooled and newer bikes have a resistor in the key cylinder\u2026

To change to an old key, you need to install a resistor. <\/a>


Google “key cylinder resistor motorcycle.”
This is an Inazuma 1200 Katana, so I fumbled around trying to find where it is\u2026 <\/figcaption>It was on the main key side, so we’ll reuse it as-is without touching it. <\/figure>\n\n\n\n
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We left the Watanabe coil wires on the connector. To avoid mistakes and reduce future hassle, it’s good to label them with a label maker. <\/figcaption><\/figure>\n\n\n\n
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Now we thread everything through (;\u2200;). It’s better to be gentle and not put stress on the harness.
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We reinstall the Moto-Eazy (obsolete term?) and the light relay.

The type where the relay comes to the headlight side\u2026 I hate it. It’s super annoying.
I can’t exactly tell him to swap it for a Daytona\u2026 so we installed it.
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I think it’s better not to co-bolt unnecessary things to the battery terminal.
But since it’s a direct-to-battery relay, what about the positive besides the ground?

The starter relay terminal (BT side) = battery positive, so you can use that too.
This time we used the generator output = battery positive. But!

Getting battery positive = fuse is essential \u2192 aftermarket fuses are\u2026 well, I was hesitant, but looking at the existing fuse box, there’s space!

We got terminals and wiring from a junk connector and made a tap like this.
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Here it is. It’s a terminal that accepts micro fuses, but\u2026 there’s no marking and I wonder who made it. If you can get this, you can add ports to the existing fuse box.

Shall we all search for it? <\/figcaption><\/figure>\n\n\n\n
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We warped quite a bit and ended up with the tachometer not working\u2026
Finally found the 400 wiring diagram\u2026 I get it now.

On the 400, the tach signal line = igniter.
On the 1200, the tach signal line = coils 2 & 3 and igniter.

When using Watanabe, there’s no tach signal line at the stock tach wire location.
We tapped from the Watanabe blue wire and fed it into the harness to clear it up. <\/figcaption><\/figure>\n\n\n\n
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We gun-coated both sides. <\/figcaption><\/figure>\n\n\n\n
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The pedal has sealed bearings, so we had to remove them and lubricate from the outside. <\/figcaption><\/figure>\n\n\n\n
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He asked to change the carb shim from 0.5 to 0.3\u2026 Really? It’s happening. We swapped it out. <\/figcaption><\/figure>\n\n\n\n
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He asked us to measure the disc thickness\u2026 and we did. <\/figcaption><\/figure>\n\n\n\n
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We swapped in Golden Cruiser DOT4 brake fluid. <\/figcaption><\/figure>\n\n\n\n
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Well, I keep learning things I didn’t want to learn, I think to myself.

Harness replacement takes more time figuring out the layout than actually doing the swap.
If you just swap it without thinking, it shouldn’t take more than two hours\u2026 (*\u00b4\u0414\uff40)

That wraps up this job. <\/figcaption><\/figure>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":2,"featured_media":42939,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"","swell_btn_cv_data":"","footnotes":""},"categories":[1924],"tags":[162,169,120],"class_list":["post-42969","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-everyday-events","tag-electric","tag-main-harness-replacement","tag-oil-cooled-katana"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/42969","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/comments?post=42969"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/42969\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/42939"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=42969"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=42969"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=42969"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}