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

[Mr.Fantastic]

Well I have came to my first issue with the bike. Started off riding down to hermann on 94 with mike. All is well. Average speed 110 the whole way down 94hwy. No issues. We got to hermann and stopped at the RR tracks. Shut the bike off, waiting for the train to pass. Went to start the bike and the button to start the bike won't work. So I popped started it. Then mike sees my head light is not on. My bright light won't work as well. No lights period. My brake light works.

So we took the seat off and checked all fuses. Nothing bad. Turn the key on and squeezed the clutch in, and used a screw driver on the battery wire to starter wire box. The bike starts right up. 30amp fuse is good as well.

So I'm thinking the push button for the starter has gone out. When I jumped it with the screw driver, this tells me the switch for the clutch safety is working, and the starter is good. Any one have any other ideas?

[mike93hatch]

most bikes have a headlight cut-off switch incorporated into the engine start button so that may be why your headlights arent working either... im starting to think it is the switch also....

[earz]

Will it start in neutral, but not in gear, or no start in either?

I'd suspect either faulty clutch switch or faulty side stand switch. Suzi's are dumb and need the clutch switch all the time. It is a N.O. switch, so you can find the 2 wire connector and jump it to bypass it. If it starts with that bypassed, that's your problem. If it doesn't start, do the same to the side stand switch. The connector for it is likely under the fuel tank though.

[Mr.Fantastic]

Its always in neutral when I start it. I jumped the wires under the seat with the kick stand down, clutch pulled in and it started. I'm still swing towards the push start button.

[earz]

What wires under the seat?

[Mr.Fantastic]

You have the positive wire from the battery to a fuse link box. On the other side of the box, the wire runs to the starter. Tap them together(screw driver) and power goes to starter. Bike then starts.

[earz]

That fuse link box is the starter relay, so you bypassed the starter relay. That bypasses any and all safety switches on the starting circuit. The clutch switch is wired directly to that relay. If it is not working, the push button on the right handlebar will not work either. The clutch switch wires are black/yellow and black/white. Unplug them from the switch on the bottom side of clutch lever and put a wire jumping the two connectors and try to start it. If it starts with the connectors jumped, the clutch switch is your problem. If it still doesn't start, then your problem is likely with the side stand switch or possibly the ignition switch.

Jumping across the starter relay is the same as hooking 12v directly to the starter. It will turn as long as nothing is causing it to bind. That will get the bike started, but there is absolutely no way to diagnos the ACTUAL problem.

Something to consider; the starter push button is not sold separately. You have to buy the whole right side switch housing (approx $90 new), while a clutch switch is about $10. Another thing to consider, in the 6-7 years I have been working on bikes, I have seen a lot of clutch switches malfunction, but not one starter button issue (on anything newer than the early 90's anyway). I'm just trying to help save you some money, but if you want to spend the $90 for a new starter switch - feel free.

[Mr.Fantastic]

Everything you said is right on the money. Hit the nail right on the head. I will check the clutch switch Sunday. I didn't think the clutch safety switch ran to the starter relay box, thought it ran to the ecu or some other signal to slow the start button to have power. I told mike the same thing while we were looking at the bike about jumping the switch. Just didn't have a jumper wire on me. Had to hurry home, cause of no headlights.

[mike93hatch]

Originally Posted by earz

That fuse link box is the starter relay, so you bypassed the starter relay. That bypasses any and all safety switches on the starting circuit. The clutch switch is wired directly to that relay. If it is not working, the push button on the right handlebar will not work either. The clutch switch wires are black/yellow and black/white. Unplug them from the switch on the bottom side of clutch lever and put a wire jumping the two connectors and try to start it. If it starts with the connectors jumped, the clutch switch is your problem. If it still doesn't start, then your problem is likely with the side stand switch or possibly the ignition switch.

Jumping across the starter relay is the same as hooking 12v directly to the starter. It will turn as long as nothing is causing it to bind. That will get the bike started, but there is absolutely no way to diagnos the ACTUAL problem.

Something to consider; the starter push button is not sold separately. You have to buy the whole right side switch housing (approx $90 new), while a clutch switch is about $10. Another thing to consider, in the 6-7 years I have been working on bikes, I have seen a lot of clutch switches malfunction, but not one starter button issue (on anything newer than the early 90's anyway). I'm just trying to help save you some money, but if you want to spend the $90 for a new starter switch - feel free.

this all sounds good...but what about the headlights that stopped working at the same time? doesnt the starter button have a headlight cuttoff? or where is that located?

[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?
http://cgi.ebay.com/ebaymotors/03-04...item3cbab74013