05 gsxr 600.....issues with headlight/wont start.

[earz]

Originally Posted by Mr.Fantastic

Well I have figured out what is the problem. It is in fact the start button. I took it apart and the little metal piece inside that allows contact to the starter, has melted. Not allowing it to do its job. I don't need the whole assembly just the white plastic piece inside the starter button. Any ideas where to buy just that?

Still haven't figured out why the lights are not coming on. Have to solve one issue at a time.

Considering this is for a 1000, will the insides still be the same?
03-04 SUZUKI GSXR 1000 Right Bar Switch Start Button | eBay

Melted parts = possible short somewhere?

You'll have to find a used switch housing to rob internal parts. Suzuki only sells it as a complete assembly. Not sure if the 1000 switch from one year prior will be the same or not? Only one way to find out - find someone local that has one and take theres apart. or buy the one from eBay and hope it works.

If you find what caused the melted contacts, I bet you'll find your headlight issue as well. I'd pull the cowling pieces under the bars (around the gauges, the ones facing towards the sky?) off and inspect all wiring you see. Nothing should be melting under any circumstance, not even 110MPH for 100 miles. That's why God invented fuses. :P

[Mr.Fantastic]

Does not really mean there is a short. If you crank on the start button for to long, 12v going through that little piece of metal, it could get really hot and melt the plastic that's holding it. Bike has 19k on it now. There is a spring under the little metal piece as well. If that spring got moved out of line, causing it not to move the metal piece up to make a good connection. That could be the short. Bad connection there and not a solid one causes heat.

[earz]

True, but the big current draw from operating the starter motor is handled by the starter relay. The start switch should draw very little current. If there was not good contact at the switch, then yeah there'd be higher resistance which would cause some extra heat, but I wouldn't think it'd be enough to melt plastic - unless of course the button was held for several minutes straight.

Let us know if the new switch fixes it and what you figure out on your headlights.

[mike93hatch]

dave, you figure anything out with the headlights?