Suzuki GSR600 (2008) won't start ☹️

[colinM]

I'm having an issue with my bike I had to get it towed at the weekend because it wouldn't start.

The main headlight high/low is not working and the bike won't start (no ignition, it won't even try) I've charged the battery up. I think there's a short on the high and low beam fuses they are both connected to gnd. I've lifted the tank and disconnected every plug and connector I can find. left and right controls, dash etc.. but this gnd short is still there. The negative of the battery terminal has a connector coming from it that goes into the writing harness (gnd)

if I disconnect that , the gnd on the harness side is what's connected to the headlights.

I have a writing diagram but these should ask be positive connections I don't see a point which they would intersect.

Any tips on how to solve this issue

[Easy-X]

Sorry but you're painting a confusing picture:

Is the bike entirely dead? As in turn the ignition on there's no neutral light or anything else.

If the bike isn't entirely dead what is working? Does the fuel pump prime, does the starter relay click... anything at all.
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Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[colinM]

[Pete.]

The wiring diagram you've posted is for a different model and 7 yrs older at that.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[colinM]

[Hong Kong Phooey]

You've checked sidestand, tipover, clutch and emergency switches?

Have you pulled the fuses for the lighting circuit and tried?
If there's a short on the lighting circuit it should have blown the fuse.

From what you describe everything works apart from lights and it lights the dash like it's good to go but won't spin the starter. Try tapping the starter a few times.

There's a 30A fuse for that usually located near the battery for the starter. Check battery main connections too. These can be loose enough for low power stuff but not tight enough to give the amps for the starter.

If it is fuses, you'll need to trace the cause or there's a chance you'll be stranded again.
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'81 CG125, '97 FZS600 : '99 CBR600F4, '09 KTM RC8

[colinM]

[Islander]

[colinM]

[Pete.]

[colinM]

I'll give that a try!
I did check the voltage but I didn't check across the spades just from the battery - to the bulb connector. Probably won't get back near it until the weekend unfortunately.

[Pete.]

If you've put the meter from battery negative to bulb feed terminal and got a low reading then you've got a supply problem.

The closest wiring diagram I can find to it is for a 2007 GSXR750, so here's what to check based on that. Put the black lead of the meter directly on the battery and use the red for testing.

Power from the battery goes to the solenoid then out through the 30A fuse there (via a red wire) to the ignition switch AND directly to fuse 5 and 6 (signal and fan). This is so that the hazards and fan can run with the ignition off.

So if you check the voltage coming in at fuse 5 or 6 and it shows battery voltage then all that section is good.

That red wire feeds the ignition switch and with the switch on it comes out via the orange wire which feeds fuses 3 and 4 (as well as feeding the RH switch cluster).

So, turn the ignition on and check the voltage feeding fuse 3 or 4. If it is 12-13v then the ignition switch is good.

Now that orange wire feeding fuses 3 and 4 also feeds the headlights via the starter button. When the button is not pushed, the switch is closed and the lights will be on. When you push the button the circuit is broken and the lights go out to reduce the load on the battery when cranking.

Since you say that your bike won't crank and that the lights won't work one would suspect that the problem is within the push-button switch for starting the engine inside the right switch cluster.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[GettinBetter]

Good post Pete....Had that with my last bike.

Has the OP recently fitted any addition front lights to the bike?

[colinM]

Bike is 100% standard.

[colinM]

[colinM]

Thanks all for your help and suggestions.

Pete you were spot on, the push start was the culprit.

I've removed it and the contacts were all tarnished also the plastic was a little warped, after cleaning with a fiberglass pencil, smoothing off the lump in the plastic and cleaning with Alcohol it's still playing up.

I can't find a replacement part, however I can find some gsxr ones slightly different (different connector) but I may be able to use the actual switch mechanism. It's that or I find an aftermarket start switch and light switch. Which might not be so bad as being able to turn off the main headlight could be useful (topping up low batteries etc)

[Hong Kong Phooey]

Good excuse to fit a quick action throttle...
https://www.ebay.co.uk/itm/283635952247?var=0
____________________
'81 CG125, '97 FZS600 : '99 CBR600F4, '09 KTM RC8

[colinM]

[Easy-X]