It sounds like you may need to reset the power manager (PMU). See this article: <http://docs.info.apple.com/article.html?artnum=14449>
Thanks for the suggestion mark, although I have already tried this with no luck.
This is a classic symptom of either a bad battery or a DC/DC converter problem.
When your iBook is switched off, the battery is subjected to higher charging currents (because the computer isn't siphoning off current for its own activities). It sounds like the charge circuit is detecting an overcurrent or overtemperature condition (maybe erroneously) and stopping the charge process. When the book is switched on, this is happening intermittently. When it's switched off and the charger goes into fastest charge mode, it's happening 100% of the time.
If you can test with another battery, I'd do so.
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