Suzuki GSX-R 1000 Service Manual: Electrical parts connector / coupler
- Faulty fi system is often related to poor electrical contact of connector/coupler. Before servicing individual electronic part, check electrical contact of the connector/coupler.
- When connecting a connector, be sure to push it in until a click is felt.
- With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully to engage the lock when connecting.
- When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.
- Inspect each terminal on the connector/coupler for looseness or bending.
- Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed, possibly resulting in poor electrical contact.
- Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material which could impede proper terminal contact.
- Before refitting the sealed coupler, make sure its seal rubber is positioned properly. The seal rubber may possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber improperly positioned, it may result in poor water sealing.
- Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.
When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (rear) of the connector/coupler.
- Coupler
- Probe
- When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female terminal. Never push in the probe where male terminal is supposed to fit.
- Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.
- Coupler
- Probe
- Where male terminal fits
- Avoid applying grease or other similar material to connector/coupler terminals to prevent electric trouble.
Precautions for electrical circuit service
When handling the electrical parts or servicing fi
system, observe the following points for the safety of the
systems. ...
Clamp
Clamp the wire harness at such positions as indicated in “wiring harness
routing diagram” in section 9a .
Bend the clamp properly so that the wire harness is
clamped securely.
...
Other materials:
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
...
Cooling circuit inspection
Do not open the radiator cap when the
engine is hot, as you may be injured by
escaping hot liquid or vapor.
When removing the radiator cap tester, put
a rag on the filler to prevent the engine
coolant from spraying out.
Inspect the cooling ...
Carrying a passenger
Carrying a passenger, when done
correctly, is a great way to share
the joy of motorcycling. You will
have to alter your riding style
somewhat since the extra weight
of a passenger will affect handling
and braking. You may also need
to adjust tire pressures and suspension;
please refer to the ...