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