Katana Gear Position Indicator Page 6
Mounting the Display
On the left is the display mounted in the unused hole in the gauge cluster. You will have to remove the gauge cluster and disassemble it. If you have the indiglo gauge faces installed like I do from PimpGauges.com you should be familiar with the inside of the cluster. Now is also a good time to replace the white background lights with blue LEDs since you have the cluster apart. I had to cut and remove a small section of white plastic to get the display to fit. **IMPORTANT NOTE!** MAKE SURE TO SOLDER THE WIRES TO THE DISPLAY BEFORE YOU MOUNT IT! If you don't you will have to rip it out and start this part over. I routed the wires through an unused hole in the back of the cluster. To hold the display in place I tacked it in with super glue on two sides. I then filled in the other two sides with clear silicone.
Now to cut a hole in the faceplate that goes over this section. I can't stress enough how important it is to take your time on this part. Suzuki does not have a part number for this little piece of black plastic. As far as I can tell you can't order it if you mess it up. To get the hole right I put the face plate back on and marked where the center of the display was. I then drilled a small hole in it. From that hole I gradually removed more plastic using a Dremel tool and cutting bit until I had the hole the right size. I used a sharp knife to clean up the cuts. MAKE SURE TO CUT FROM THE BACK! That way if you accidentally scratch the plastic out side of the hole area it won't be seen. The film you see over the holes is 30% visibility windows tint. Once you install it you won't be able to tell the edges of the hole.
Here is a picture of the front. I'm sorry it isn't very clear but you can see what I'm talking about. Once it is installed in the cluster it's almost impossible to tell you have a hole there for the display.
I also put a small piece of tint on the display. It helps to hide it. Don't worry about brightness because it will be plenty bright.
And here is a picture of it all reassembled. Looks factory doesn't it? To get the wires out I routed them next to the plug in the back of the cluster. When I reinstalled it on the bike I poked a hole in the rubber boot that goes over the plug and ran them out of the hole.
