2003 SUZUKI SV1000 Electrical System Problems

THE CHARGING SYSTEM MAGNETS DETACHED FROM THE FLYWHEEL/ROTOR (INTERNAL TO THE MOTOR), CAUSING AN ISSUE WHERE THE CHARGING SYSTEM WAS NOT FUNCTIONING PROPERLY. THIS IS A SAFETY ISSUE BECAUSE THE MAGNETS COULD HAVE BECOME DISLODGED ENOUGH TO CAUSE A CATASTROPHIC AND IMMEDIATE ENGINE SEIZURE/FAILURE, RESULTING IN I A CRASH. THANKFULLY, I CAUGHT THE ISSUE BEFORE IT BECAME SEVERE. AFTER A BIT OF ONLINE RESEARCH, I HAVE FOUND THIS TO BE A VERY COMMON ISSUE FOR SUZUKI BIKES EQUIPPED WITH THIS FAMILY OF ENGINES. NUMEROUS INSTANCES CAN BE FOUND ON THE SV650, SV1000, AND ALL MODELS OF THE V-STROM. I HAVE NOT YET CONTACTED SUZUKI REGARDING THIS MATTER, BUT PLAN TO DO SO TODAY. IT IS MY UNDERSTANDING THAT A CASE HAS BEEN OPENED TO LOOK INTO THIS MATTER. I BELIEVE THE CASE NUMBER IS [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

MY SV1000 HAS EXPERIENCED PROBLEMS WITH ITS CHARGING SYSTEM THAT AFFECTS THE ENTIRE ENGINE. I CAME TO FIND IT WAS A HEAVILY DOCUMENTED ON PUBLIC ONLINE FORUMS SUCH AS SV-PORTAL.COM AND HAS AFFECTED ALMOST ALL SV1000 OWNERS. THE MAGNETS, WHICH ARE GLUED TO THE INTERIOR OF THE STATOR ROTOR, BREAK FREE OF THEIR EPOXY BOND AND SHATTER INTO PIECES INSIDE THE ENGINE CASE. THIS IS A MAJOR SAFETY ISSUE AS DAMAGE TO THE STATOR/ALTERNATOR IS CERTAIN AND FRAGMENTED MAGNETS ENTER THE TRANSMISSION, OIL PAN, CLUTCH AND OTHER ENGINE SYSTEMS. WHEN ANY OF THESE SYSTEMS ARE CAUSED TO FAIL BY THE BROKEN MAGNET PIECES OR CHARGING SYSTEM FAILURE AT DRIVING SPEED THE RIDER AND ALL NEAR BY MOTORISTS ARE AT SERIOUS RISK. THIS PROBLEM IS WIDESPREAD AND AFFECTS ALL YEARS OF THE SV1000. THE SAFETY ISSUE OCCURS AT VARYING MILEAGE BUT IT IS CERTAIN THAT VEHICLES WITH MORE THAN 15,000 TO...

1. BIKE WOULD COMPLETELY GO DEAD WHILE RIDING, GAUGES GO BLACK AND BIKE WILL NOT CRANK. IT HAPPENED ON MULTIPLE OCCURRENCES 2. PROBLEM WAS A TOTAL LOSS OF ELECTRICAL POWER, THIS MEANS NO LIGHTS, NO IGNITION, NO GAUGES, LIKE IF SOMEONE HAD TURNED OFF THE IGNITION SWITCH. 3. I TROUBLE SHOT THE PROBLEM BECAUSE THE MOTORCYLCE WAS OUT OF WARRANTY AND THE SHOP WANTED TO CHARGE ME A DIAGNOSTIC FEE TO LOOK AT IT. I FOUND THE CONNECTOR ON THE WIRE HARNESS THAT GOES TO THE IGNITION SWITCH BLACK AND BURNT FROM THE WIRES SHORTING TOGETHER. I BYPASSED THE CONNECTOR WITH A NEW CONNECTION. THE OLD CONNECTOR IS STILL AVAILABLE. *JB

WHILE RIDING THE MOTORCYCLE THE ELECTRONICS AND ENGINE BEGAN TO CUT-OUT INTERMITTENTLY. UPON INSPECTION, IT WAS FOUND THAT THE CONNECTOR BETWEEN THE IGNITION SWITCH AND THE IGNITION RELAY HAD MELTED AND WAS SHORTING OUT. THE FUSE ON THE CONNECTION DID NOT BLOW. THERE WAS NO MOISTURE PRESENT OR OTHER EXPOSURE.*JB