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The Spark Plug Gap for the Bike is 0.6-0.7 mm or (0.024-0.028 in. It takes Roughly 3 and 1/3 Quarts. I would simply add 3 quarts and then fill it with the last bit after filling the Filter.
Start the bike and put a voltmeter across the battery; you should get a reading of probably around 13.5V. If you're getting only about 12V or less, the battery isn't charging. From there you will need to go to the alternator terminal on the regulator and see if you're getting more than 12V. If you are, the regulator is probably bad, if not it could be a bad rectifier if there is a seperate rectifier or a bad stator. Good luck and safe riding.
Your generator is on the left as you sit on the bike. The GS/gsx Suzukis do have issues with charging the battery.
1. Charge the battery.
2. Use a multimeter/voltmeter across the battery, do you get 13.5volts dc or more? You may need to rev the bike to 2-3000 revs.
3. If the meter just shows battery voltage, you need to check the regulator/rectifier unit. This will be under the side panel (usually left side) and will be a square metal unit with cooling fins. Check all the connections are clean and rust free, ncluding all the earth connections. Test your charging again.
4. If its still not charging, trace the 3 wires that come from your alternator and connect to your regulator. Disconnect them and use a meter to check between each of the 3 wires. You should get 60-90 volts AC. If not, you need new alternator windings. If you get the correct reading, you need a new regulator rectifier unit.
For an 81, a lot to check. The charging system is not a simple affair. You would need to check the wiring, output of the stator and of course, the rectifier / regulator combo among others. Start with the terminals / connectors of the stator to the regulator.
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