KATANA CHARGING SYSTEM

OK boys and girls. If you don’t know already, the Suzuki charging system stinks. I recommend replacing the stator and the regulator / rectifier with aftermarket components before your harness melts and your battery boils over and explodes.
For the katana, there are two extra wires that are not needed. They are Green with White tracer, and White with Red tracer. The stator connects to one and the regulator / rectifier connects to the other. where do they go? They run through the harness upto the right hand control plug and loop around back. It is a very long way to connect the stator to the regulator / rectifier. A better idea is to just connect all three wires coming from the stator to the regulator.
The regulator will have two more wires. Black, which is ground and Red, which connects to the red wire on the harness which feeds the battery. The aftermarket stators and regulators all have the same color wires because it doesn’t matter how you connect the three. Just plug them all into the regulator. In the picture below you can see the Red/white plugged into the Green/white. That is just a closed loop up to the right hand control plug and back down.

If you use another type of reg/rec it may have another wire which is probably the status wire that tells the reg/rec how the battery is. Connect that directly to the battery. If you don’t, and connect it to a switched power wire, you run the risk of over charging the battery as the reg/rec may see less voltage due to resistance and corrosion in the wires.
A side note, there are only two types of reg/rec controlers. One for lower output stators and one for higher output stators. As far as the katana is concerned, any regulator / rectifier will work on our bikes. It is just some have more wires than others. They will all do the same job.