Major Katana problems first time out!

[Miyamoto]

Hey Everyone!
So the weather broke in Chicago today and I decided it was time to ride:
My bike's been in the garage since I got it, so I went down there, installed my Yosh pipe and a rotating led brake light thingie before setting off....or at least, that was the plan.

I think it may have been the LED light that did it, but suddenly my battery was drained and the engine wouldn't roll over. The 'Neutral' light went out and never came back on. I got my buddy to jump my battery with his bike and took out the LED light after doing some minor troubleshooting, which seemed to get everything working again, but my console doesn't light up like before and now my bike cuts off everytime the kickstand is down...regardless of if I'm in Neutral or not. I know it's not supposed to start in 'N' with the stand down, but this is the first I've seen of a bike cutting itself off in it.

I checked the fuses and they seemed fine and I suppose its possible I burned a light/sensor/relay somewhere, but I dunno how. The LED was definitely a 12V and seemed to work fine (ground problem maybe? I dunno).

So...if anyone can explain to me exactly what the proper functioning of this Suzuki Katana "kickstand-start-don't-start" thing, I would be very grateful.
Also, if you have any advice/input for me regarding those lovely lights not coming on again, I would be very grateful (only the oil light shows now...and yes, there's oil in it.)

Another thing I should mention is that there was pretty much zero gas in the tank and I ended up going to fetch some in my truck. Could this have had some bearing on the problem?
I dunno. The good news is that I did go riding afterwards, but my bike went off everytime I put down the k'stand...which sucked.

So.......and ideas, geniuses???

[axel_2078]

The bike should start up fine with the stand down while in neutral. And if the bike was uprighted and in gear and you decided to shift into neutral, you could put the sidestand down and it shouldn't die. The only time the sidestand should kill the engine is when is when it's in gear and you try to put it on the sidestand. Also, the bike should not start with the sidestand down if it's in gear.

[jsvickers]

Well, I've never worked on a bike, but I did buy the manual for my 04 Katana with the intention of learning about them a bit...

Looking at the diagram of the Side-Stand/Ignition Interlock System, it looks like there is a turn signal/side-stand relay that could be your problem. It may also just be the neutral indicator light switch.

I really don't know much about this stuff and the manual doesn't show where to find the relay, but I'd guess it shouldn't be too hard to track down. It's got 5 wires leading into it.

Orange with Yellow tracer leading to a fuse
Blue with Black tracer leading to the neutral indicator light
Orange with Black tracer leading to the engine cutoff switch
Green leading to the side stand switch
Blue leading to the neutral indicator light switch

If either the neutral indicator light switch or the relay itself are bad, then the bike may not run with the side stand down, even in neutral. The relay could also be causing the neutral light to not light up.

If you have more experience with this stuff than me, then I can scan the pages from the manual and let you take a look at it yourself.

*edit*
Actually, the manual does show where these parts are and they use pretty crappy close-up pictures that probably won't scan well. The relay is under the seat, possibly by the fuse box, it's hard to tell from the crappy picture. The neutral indicator light switch is under the fairings. I'd have to go look at my bike to have a chance at telling you where it is. The picture isn't useful to me. It is probably on the left side of the bike and has a blue wire leading to the relay and a black to ground.

[Miyamoto]

Thank you....its a good start.

[87gsxrnut]

Well, I told you before not to put those damn LEDs in there for EXACTLY that reason. Sounds like a grounding issue to me. I have had to "undo" so many Neon and LED hack jobs it isn't funny.

Imagine, now the harness isn't working properly. Now, even if you DO get it to work right, will you trust it 400 miles from home?

Uh, that is a Suzuki safety feature (sidestand switch).

- Nut

[Miyamoto]

Whoa, hang on a sec. We're getting ahead of ourselves here.
I didn't put in the LEDs...not yet anyway.
This was just a LED BULB that fits in the same socket that your regular stoplight bulb goes into. I'll admit to making a mistake, no problem, but how was I to know that changing a lightbulb would so adversely affect the wiring in my bike...if that's what you're telling me?
Anywho...any ideas on how I can fix it, or will I just be chastised endlessly?
Thanks again

[jsvickers]

I looked under my seat this morning and the relay is the small module directly beside the fuse box. It unplugs pretty easily. The manual has a procedure for testing the various components in the module. Assuming it's the relay and not the indicator light switch, given your symptoms, my guess is that there is a burned out diode that is not allowing the module to turn on the relay if the bike is in neutral.

I forgot to bring the manual in to work with me, so I can't tell you offhand what the procedure is for checking the module. I'll try to let you know this afternoon when I get home.

I didn't take my fairings off to find the indicator light switch, so I can't help you too much on it's location

[Miyamoto]

Thanks jsvickers...I really appreciate your help.

[Louis]

You definitely should buy the manual too Miya.

[FIVEINCH]

Did you happen to check the blinker-fluid? You may be low. I hear those crazy-spinny-LED-brakelight-thingies suck up a lot of juice.

Check all of your fuses. Not only are you energizing a light, but now you're trying to spin a dc motor. You may be using more current than the circuit was rated for. And then there's the issue of quality in regards to your crazy-spinny-LED-brakelight-thingy.

[inspiron]

And be sure to syncronise the blinkers again - you'll need a special guage for that.

I've also heard that re-balancing the bike with a gyroskope helps, but only if you are living more than 1500 feet above sea level.

[Miyamoto]

Blinker Fluid...I gotta remember that one.
Thanks a million for all the help y'all.
My Service Manual on CD is on the way.

[finch20th]

you must be talking about the ufo lights....????

[jsvickers]

I just reread your initial post and had forgotten that you said some of your console lights are out. Exactly which ones?

Trying to read the wiring diagram makes me go cross-eyed after a minute or two, but I don't see any immediate connection between the side-stand relay and any console lights except possibly through a fuse.

[Miyamoto]

The Neutral Light doesn't come on at all.
In fact, normally when you turn the key the whole console lights up for a sec.
Not anymore....