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CHAPTER EIGHT
 
ELECTRICAL SYSTEM
 
This chapter contains operating principles, serv-ice procedures and test procedures for all electricaland ignition components. Information regarding thebattery and spark plugs are covered in ChapterThree.
 
The electrical system includes the following sys-tems:
 
a. Charging system.
 
b. Ignition system.
 
c. Starting system.
 
d. Lighting system.
 
e. Directional signal system.
 
f. Switches.
 
g. Various electrical components.
 
Tables 1-5
are located at the end of this chapter.
 
 NOTE 
 
Where differences occur relating to theUnited Kingdom (U.K.) models they areidentified. If there is no (U.K.) designa-tion relating to a procedure, photo or illustration it is identical to the United States (U.S.) models.
 
 NOTE 
 
 Most motorcycle dealers and parts sup- pliers will not accept the return of anyelectrical part. When testing electricalcomponents, three general require-ments to make are: (1) that you followthe test procedures as described in thischapter; (2) that your test equipment is
 
 
working properly; and (3) that you are familiar with the test equipment and itsoperation. If a test result shows that acomponent is defective, have a Suzukidealer 
 retest
the component to verify your test results prior to purchasing thenew part.
 
ELECTRICAL CONNECTORS
 
The Suzuki Interceptor is equipped with manyelectrical components, connectors and wires. Corro-sion-causing moisture can enter these electrical con-nectors and cause poor electrical connections leadingto component failure. Troubleshooting an electricalcircuit with one or more corroded electrical connec-tors can be time-consuming and frustrating.
 
When reconnecting electrical connectors, pack them in a dielectric grease compound. Dielectricgrease is especially formulated for sealing and wa-terproofing electrical connectors and will not inter-fere with the current flow through the electricalconnectors. Use only this compound or an equiva-lent designed for this specific purpose. Do
not 
use asubstitute that may interfere with the current flowwithin the electrical connector. Do
not 
use siliconesealant.
 
After cleaning both the male and female connec-tors, make sure they are thoroughly dry. Pack one of the connector halves with dielectric grease com-pound before joining the 2 connector halves. Onmulti-pin connectors, pack the male side and onsingle-wire connectors, pack the female side. Use agood-size glob so that it will squish out when the twohalves are pushed together. For best results, the
 
compound should fill the entire inner area of theconnector. On multi-pin connectors, also pack thebackside of both the male and female side with thecompound to prevent moisture from entering thebackside of the connector. After the connector isfully packed, wipe the exterior of all excessive com-pound.
 
Get into the practice of cleaning and sealing allelectrical connectors every time they are unplugged.This may prevent a breakdown on the road and alsosave you time when troubleshooting a circuit.
 
Always make sure all ground connections are freeof corrosion and are tight at various locations on thebike.
 
BATTERY NEGATIVE TERMINAL
 
Some of the component replacement proceduresand some of the test procedures in this chapterrequire disconnecting the battery negative (-) leadas a safety precaution.
 
1.
 
Remove the bolt and disconnect the battery negative
(Figure
1) lead.2.
 
Reach into the battery case and move the negativelead out of the way so it will not accidentally makecontact with the battery negative terminal.3.
 
Connect the battery negative lead to the terminaland tighten the bolt securely.
CHARGING SYSTEM
 
The charging system consists of the battery, alter-nator and a solid-state voltage regulator/rectifier
(Figure
2).
 
Alternating current generated by the alternator isrectified to direct current. The voltage regulatormaintains constant voltage to the battery and electri-cal loads (lights, ignition, etc.) regardless enginespeed and load.
 
A malfunction in the charging system generallycauses the battery to remain undercharged. To pre-vent damage to the alternator and the regulator/rec-tifier when testing and repairing the chargingsystem, note the following precautions: 1. Alwaysdisconnect the negative battery cable, as describedin this chapter, before removing a component fromthe charging system.
 
 
2.
 
When it is necessary to charge the battery, removethe battery from the motorcycle and recharge it asdescribed in Chapter Three.3.
 
Inspect the physical condition of the battery.Look for bulges or cracks in the case, leaking electrolyte or corrosion build-up.4.
 
Check the wiring in the charging system for signsof chafing, deterioration or other damage.5.
 
Check the wiring for corroded or loose connections. Clean, tighten or reconnect as required.
Leakage Test
 
Perform this test prior to performing the outputtest to determine if some electrical component isremaining on and draining the battery.
 
 NOTE 
 
 Due to the location of the battery and its leads it is necessary to remove thebattery from the motorcycle to per- form this test.
 
CHARGING CIRCUIT
 
Ignitionswitch
Color CodeY Yellow
 
B Black or Black/white OOrange or Orange/black RRed or Red/white
Regulator/rectifier
Load
Battery
 
AC generator
 
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