Join Date: Sep 2019
Location: Ocean Springs, MS
2002 GSXR 750 Lots of Problems (Need Help)
2002 GSXR 750 1x Owner (Me)
80K miles (freshened up at 50K) Lots of street miles/track days/WERA, but haven't really ridden it in years because of problems.
Current aftermarket parts on the bike: BMC Race filter (Clean), Yosh full exhaust, 1/4 turn throttle, chain/sprockets, Disconnected Power Commander III.
I have the factory service manual, and have always felt like I'm a decent mechanic but have a basic understanding with electrical issues.
Compression: 180-190 on all cylinders, Wet compression 200-210. (Using a harbor freight C-tester)
The last time I really was able to ride it successfully was about 2013.
My current problems:
1. I put new (stock) headlight bulbs back in and cycled the key. LOW beams and speedo were on, but when I clicked the HI beams I lost all lights and the speedo. Found and cleaned corrosion on the wiring harness under the air duct and now my lights work, but my speedo only lights up (no tach/or gauge information, just the backlight) I cannot find any other corrosion and also tried swapping the ECM but no change. Ideas?
2. I believe the bike has electrical issues because of poor running conditions (bike runs better when cold, but horrid when it gets hot). I replaced all injectors/coil packs/plugs/sensors/ECM/fuel pump/Stator/Rectifier/Battery with no luck. I have used 2x multimeters all over the bike. The original stator was good on Ohms, each leg was 22v at 5k, and was charging the battery at 14.2-14.5. The problem was when it hit 150 degrees exactly it would overcharge 14.7-14.9 and start running a lot worse including dropping the idle rpm from 1200 to 1000. I replaced the stator, rectifier, and battery with all of the OEM parts just like it had in it. THE NEW PROBLEM. New stator will hold 14.2-14.3 constantly until I take it down the road then it starts running bad so I come back and read the battery and its only putting out 12.7 (not charging). All plugs and contacts are clean. Any Ideas?
3. I thought I smelled burning coming from the top of the motor near the coil packs so I pulled the plug off the back when running. 2x out of the 4 will almost let the engine die and 2x have an almost in noticeable change like they are bad. So I swapped them with each other and with 2x other sets I have and get no change almost like the harness is bad. I checked the voltage on each coil pack while running and they are all within spec per the service manual. Ideas?
4. With the airbox off there is a very fine white vapor/smoke coming from the crank case breather. Ideas?
Last edited by EVL 750; 09-30-2019 at 07:49 AM.