05 gsxr 600 electrical problems

hey.  i have a 2005 suzuki gsxr 600.  i just rolled over 30,000 miles the other day and the gremlins came with it.  i was riding down the highway the other night and my headlight cut out.  i pulled over and turned the bike off.  when i went to try to restart it, it acted like it didn't want to start, not having enough power or something.  it seems to only start if i twist the throttle a little, which has never been the case.  i have checked the battery, battery connections, fuses, as many connections as i can find, etc.  the headlight still doesn't turn on besides occasionally flashing when i try to start it.  the high beam indicator light also does not work.  the rest of the electrical works fine (gauges, fuel pump, turn signals, brake light).  anyone have any ideas.  

thanks, tim  

Tim, I'm not too familiar with Suzuki's. I've heard others describe the same symptoms with Kawasaki's. They always head for the junction box first. The solder connections can become cracked causing a gimpy connection.I know with the Kawa's the box's can be resoldered. It takes a careful eye.

I hope others will chime in for you with their thoughts.

Good luck.  

I would get a shop manual showing the wiring diagram and with either a continuity light (for a non-power check) or a digital/analog meter look and inspect each electrical plug/jack in the electrical system for 1. Broken wires. 2. Broken pins/sockets in the electrical connections.

With the bike's electrical system turned "on" using the meter check voltages at the connectors and flex the wire bundles looking for a loose wire or broken conductors inside the wires.

Motorcycles are similar to high performance aircraft in the each have a high frequency vibration that can cause metal fatigue in wiring if it is not properly supported.

The main wire bundle from the headlight/ignition switch area is under a lot of stress and the constant flexing of turning the bars may have made an intermittant connection.  

Sources for wires and tools can be reached at the following web sites:
1.www.waytekwire.com,www.(Wire, connectors,heatshrink tubing)
2.www.painlessperformance.com(Custom wire harnesses,wire
3.wwwterminalsupplyco.com(Wire, tools,heatshrink tubing)
4.www.delcity.com(Switches,led's,wire)  

#4 should be www.delcity.net not .com  

Aa excellent spray contact cleaner treatment is the Caig Deoxit D5 from Caig laboratories out of San Diego Ca. I have used their products for many years on motorcycles and automobile electrical connectors. The company website is www.caig.com  

the same problem happened to me i can't figure it out, if you do please let me know wallae72001@yahoo.com thanks bro  

I have a 04 gsxr 600 that had the same problem in the past...the headlight intermittently flikered on and off...but i did not have any starting problems....i know the problems with the headlight though...there is a main rectangular electrical connector that consists of 20 wires that joins the instrument cluster and headlight in the front fairing with the chassis wiring harness...its located on the left side of the fairing (as viewed from sitting on the bike)..if u remove the left fairing u can see it easily its right above the left frame slider...there is a main ground wire within that connector that gets water in it and i noticed it was black around that part of the wire inthe connector like it got too hot...i cleaned out that connector with electrical cleaner and put bielectric grease in the connector and never had the problem again..give that a shot