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Suzuki GSX-R 1000 Service Manual: Charging system symptom diagnosis

Condition

Possible cause

Correction / reference item

Generator does not charge Open- or short-circuited lead wires, or loose lead connections. Repair, replace or connect properly.
Short-circuited, grounded or open generator coil. Replace
Short-circuited or punctured regulator/ rectifier. Replace
Generator does charge, but charging rate is below the specification Lead wires tend to get short- or opencircuited or loosely connected at terminals. Repair or retighten.
Grounded or open-circuited generator coil. Replace
Defective regulator/rectifier Replace
Defective cell plates in the battery. Replace the battery
Generator overcharges Internal short-circuit in the battery. Replace the battery
Damaged or defective regulator/rectifier Replace
Poorly grounded regulator/rectifier Clean and tighten ground connection.
Unstable charging Lead wire insulation frayed due to vibration, resulting in intermittent shortcircuiting. Repair or replace
Internally short-circuited generator. Replace
Defective regulator/rectifier Replace
Battery overcharges Faulty regulator/rectifier. Replace.
Faulty battery Replace.
Poor contact of generator lead wire coupler. Repair.
Battery runs down quickly Trouble in charging system Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.
Cell plates have lost much of their active materials a result of overcharging Replace the battery and correct the charging system.
Internal short-circuit in the battery Replace the battery
Too low battery voltage. Recharge the battery fully.
Too old battery. Replace the battery.
Battery “sulfation” Incorrect charging rate. (When not in use battery should be checked at least once a month to avoid sulfation.) Replace the battery
The battery was left unused in a cold climate for too long. Replace the battery if badly sulfated
Diagnostic information and procedures
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Battery runs down quickly
Troubleshooting Step Action Yes No 1 Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accesso ...

Other materials:

Specifications
Service data Electrical unit: mm Caution never use anything except the specified battery. Tightening torque specifications Note the specified tightening torque is described in the following. “Regulator / rectifier construction” Reference: for the tig ...

Cylinder head related parts inspection
Refer to “cylinder head disassembly and assembly” . Cylinder head distortion Decarbonize the combustion chambers.  Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the ...

Rear brake caliper disassembly and assembly
Refer to “rear brake caliper removal and installation” . Disassembly Remove the pad spring (1) and rubber boot (2) from the caliper. Place a rag over the piston to prevent it from popping out and then force out the piston using compressed air. Caution do not use hig ...

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