04+ No start / No Headlight fix. - GSXR.com
 
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post #1 of 32 (permalink) Old 08-06-2010, 09:42 AM Thread Starter
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04+ No start / No Headlight fix.

I've seen a bunch of threads recently about bikes not starting consistently, the headlight going in/out, etc. Most of the threads mention a combination or variation of the two problems, and the fix is to replace the right handlebar switch pod. You can recondition the starter switch for free.

Around 2004, Suzuki changed the design of the starter button. Instead of a single contact switch, its now a slider contact switch which disengages the headlight while starting, and reconnects it when the starter button is out. These new style switches are prone to corrosion build up, and therefore faulty operation.

I recently converted my 2001 front end to a 2006 front suspension, and included in that was some electrical work to switch to the newer style electrical controls on the clip ons. When doing the right pod, I noticed the headlight and starter wires were giving me weird numbers, and not working all the time, so I took it apart.

Once you get the pod off the bike, it'll look like so:



Pull the little black spacer / alignment piece out, and
Unscrew the plastic cover on top of the starter switch



Now you can unscrew the starter button and pull it out.



Starter switch is out



Now pop the two halves apart with a small screwdriver.



Here are the contacts that need to be cleaned. Sorry for the crappy picture, but if you look closely you can see 4 black lines, one on each contact. This is the corrosion build up. Lightly sand the contacts with a high grit sand paper.



All clean and shiny. Now apply a very thin layer of dielectric grease to the contacts. Ready to clean the other half.





Carefully pop the spring and contact portion out of the starter button, and run the contacts across the sand paper. Try to vary the angle slightly to cover more of the round contacts.

Reassemble. As soon as I got the pod back together, the starter button was reading perfect continuity and controlling the starter and headlight beautifully.


2011 GSX-R 750
2001 GSX-R 750 - Sold :(

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Last edited by UltimatE; 08-06-2010 at 09:44 AM.
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post #2 of 32 (permalink) Old 08-06-2010, 03:47 PM
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Thanks a bunch for doing this. It is now stickied.


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post #3 of 32 (permalink) Old 08-20-2010, 08:33 AM Thread Starter
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Glad to help out fellow riders, my pleasure. Hopefully lots of people get good use out of it.

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post #4 of 32 (permalink) Old 09-08-2010, 08:09 PM Thread Starter
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Just wanted to post a quick update. Had this switch pod running a month now after cleaning it, and its still perfect.

2011 GSX-R 750
2001 GSX-R 750 - Sold :(

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post #5 of 32 (permalink) Old 10-15-2010, 07:56 PM
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I just noticed tonight that my headlight was off once I started my bike up. Could this be the starter switch? My headlight comes on (DDM HID kit) and starts warming up. I normally let it warm up until it's at it's brightest, then start the bike. When I do that, the headlight either cut out immediately or would cut off after a split second of starting. When I would flick the high-beam switch on, the light would come on (inconsistently, sometimes it did, sometimes it didn't) with the high beam. Totally pissed me off because I was looking forward to a night ride.

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post #6 of 32 (permalink) Old 10-24-2010, 10:33 PM Thread Starter
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It very well could be, as the headlight wiring is run through the start switch, and the circuit is opened when the started button is pressed.

I believe with HID's you would want to run them on a relay off the battery though, as HID's do tend to pull a lot of current on start up.

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2001 GSX-R 750 - Sold :(

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post #7 of 32 (permalink) Old 11-28-2010, 07:58 PM
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u think maybe this is why im not getting any fire ive tried and tried but cant figure it out im thinking it could be one of the switches
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post #8 of 32 (permalink) Old 11-28-2010, 08:08 PM Thread Starter
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This switch only controls the headlight and the starter, so if the engine turns over you've gotta look elsewhere.

2011 GSX-R 750
2001 GSX-R 750 - Sold :(

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post #9 of 32 (permalink) Old 02-07-2011, 12:20 AM
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A great and very useful wright up!
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post #10 of 32 (permalink) Old 02-07-2011, 11:21 AM
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Angry

I had this problem and I bought a brand new starter switch and put it on.All was well. Well about a week later I go to back out of my drive way and I had turned to handle bars all the way to my right(pulled right side towards me) and the entire bike just dies, no power to bike at all no headlight no gage cluster, nothing. I have NO CLUe what has caused this, I replaced all of the fuses in hopes that it was simple and that I could have a easy fix but that didn't work either, any ideas here?

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post #11 of 32 (permalink) Old 02-07-2011, 02:04 PM
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I learned something new today. Good stuff.
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post #12 of 32 (permalink) Old 02-11-2011, 07:50 AM
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nobody has any input on my issue? 8(

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post #13 of 32 (permalink) Old 02-12-2011, 05:23 PM Thread Starter
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Have you checked all the connections in the nose cone? Sounds like one of them came loose and popped out when you turned sharply.

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2001 GSX-R 750 - Sold :(

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post #14 of 32 (permalink) Old 02-15-2011, 10:34 AM
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Well I found the problem I seem to have pinched a wire that connects from the ignition....sigh..... any easy fix to that or guess I will have to get it towed?

2005 Gsxr 1000
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post #15 of 32 (permalink) Old 04-20-2011, 05:41 PM
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i have an 04 750 and in the past three weeks i have had the bike die on me twice both times have been from the bike sitting for three days or more. i thought it might be a battery issue due to the fact that the battery in my bike is more than three years old and when talking to a service guy at my local cycler gear shop and he says its probably the battery saying that tyhey are only supposed to last about two and half yrs. Also with me living in an extremly hot state and having an upgraded exhaust as well as pcIII and a av outlet charger all running to the battery it may just be time for a new one. a;so jumped my battery the last time with a car maybe killed of some of the cells in the battery. what do youi guys think. also when the bike is getting used it starts up with no problem.

04' 750..........v-stacks, pc3, gafler waver rotor and brake lines, K&N filter...and the balls to ride fast and hard
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post #16 of 32 (permalink) Old 04-12-2012, 04:44 PM
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Dealer mode

You can use a wire jump and put it in dealer mode. Thats how I found out I had to reset my tip sensor on my 05 gsxr 600. The code come up in the display.
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post #17 of 32 (permalink) Old 06-19-2012, 03:52 PM
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ground issue in your wiring harness thats what mine did. check left side under ram air duct pull connector apart and see if its messed up
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post #18 of 32 (permalink) Old 10-27-2012, 10:43 AM
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Please help me out with this post! Heres the link

https://www.gsxr.com/showthread.php?t=97131
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post #19 of 32 (permalink) Old 10-29-2012, 06:00 PM
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Helpful writeup!!
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post #20 of 32 (permalink) Old 01-25-2013, 11:35 AM
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??

i have a 03 750... i never had a prob turning it over but my headlights dont work... is the starter switch the sam on the 03 as the 04??
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post #21 of 32 (permalink) Old 02-08-2013, 05:39 PM Thread Starter
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Nope, the 01-03 750 uses a single contact switch, that only controls the starter.

Things to check for headlights not working: Headlights witch (left pod), relays, fuses, and wiring.

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2001 GSX-R 750 - Sold :(

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post #22 of 32 (permalink) Old 04-10-2013, 03:37 AM
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I was having this issue.
It seems lots of issues are in this starter. There was a lot of melting of plastic causing my switch to be melted into it.

I got my switch off and I noticed a wire wasn't connected. My question is, how do I get the left wire connected like the right one.
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post #23 of 32 (permalink) Old 04-10-2013, 04:01 AM
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The wire is supposed to be soldered into the terminal in the switch block. If you do not have a nice hot soldering iron to do it quickly then the heat will transfer into the plastic and melt the block.

The pic is not good enough resolution to see if it is damaged beyond repair.

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post #24 of 32 (permalink) Old 04-10-2013, 11:21 AM
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Quote:
Originally Posted by Bala View Post
The wire is supposed to be soldered into the terminal in the switch block. If you do not have a nice hot soldering iron to do it quickly then the heat will transfer into the plastic and melt the block.

The pic is not good enough resolution to see if it is damaged beyond repair.
That is kind of what I assumed. Thank you for the response. Sorry for the shit resolution lol
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post #25 of 32 (permalink) Old 08-23-2013, 07:46 PM
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turning over but wont start

my 2007 750 wont start, it turns over but something seems to be keeping it from getting fuel and spark. is there some kind of safety switch malfunction or wiring that would cause this?
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post #26 of 32 (permalink) Old 08-23-2013, 07:59 PM
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Plenty. Tip over switch, kick stand switch, clutch position switch. Take your pick.

If you want start a new thread and post specifics in there. Tech and performance section. Most people probably wouldn't catch this post.


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post #27 of 32 (permalink) Old 01-11-2014, 10:50 AM
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well this is good to know
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post #28 of 32 (permalink) Old 05-20-2014, 08:33 AM
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so if i recondition the starter switch this should solve my problem of the headlight not working? Right now my headlight does not come on when i turn the bike on and the rpm gauge does not move. The signals don't work and my tail light is on at all times as if i were pressing the brake.
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post #29 of 32 (permalink) Old 06-01-2014, 01:54 PM Thread Starter
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Quote:
Originally Posted by birdman600 View Post
so if i recondition the starter switch this should solve my problem of the headlight not working? Right now my headlight does not come on when i turn the bike on and the rpm gauge does not move. The signals don't work and my tail light is on at all times as if i were pressing the brake.
Sounds like you have much bigger problems. The only thing the starter switch does when depressed is: Turns off the headlight, and initiates the starter. Once the switch is released, it reconnects the headlight.

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2001 GSX-R 750 - Sold :(

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post #30 of 32 (permalink) Old 12-14-2014, 10:07 AM
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Okay I have been having a similar problem with My k8 GSXR 1000.
I washed her yesterday she drove and rode fine I get home park for about an hour. come back out and go to fire her up but notice that the HL (which is an HID) is trying to turn on but will shut off.. And another problem I hear is that now my fuel pump primes but wont stop.. it keeps priming.. normally its just for a few seconds but now it just keeps buzzing bike starts and runs fine still just NO HL and the Fuel pump stays priming when bike is off and key towards ON.. HELP!! could this be my simple fix?
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post #31 of 32 (permalink) Old 03-13-2015, 03:05 AM
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Ok, so I'm an idiot lets get that out of the way. Just bought my 2013 GSXR 600 2 weeks ago, pulling out of my driveway and layed it down on the left side. The "FI" light did not turn on. I picked the bike back up, tried to start it. The lights all came on once I turned the key into ignition. The bike check kicked in once I flipped the switch. BUT, when I pull the clutch in, and try to start up the bike, the headlight switched off and the bike Will Not start. The bike is Brand New and when I layed it down it was not a hard fall at all! Please help! Stuck stranded at a buddies and don't want to have it towed.
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post #32 of 32 (permalink) Old 08-23-2015, 05:49 PM
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I just happened to stumble upon this site ! Thank goodness as this exact thing just happened to me ao I am hoping this is the problem ! Whoever made the post thanks a ton ! Wish me luck ! Lol
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