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Old 10-29-2007, 10:41 AM   #1 (permalink)
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Join Date: Oct 2007
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Default 02 Suzuki GSXR 600 Telefonica Headlight Issue

Before dropping a bunch of money for diagnostic work and just prior to stripping the harness down completely, looking for some help here for a random headlight problem, as in they only work when they want to. Hoping someone else has ran into the same issue and can give some guidance.

Troubleshootings to date:

*Know it's not the bulbs themselves because both work fine when the bike wants to light them up.

*Have pulled the windscreen and instrument panel off as instructed by repair manual and "reset" all plug-ins directly to the bulbs.

*Know it's not a fuse issue because have pulled all and all are fine.

*Bike has never been dumped, so know there is no obvious wire damage. Assume if it were wire damage/short of some sort internally, wouldn't the lights would flicker on/off during normal riding as the short is open/closed?? Have checked all harnesses and there's nothing from rubbing or standard wear/tear.

At the end of rope technical question not yet answered: Have had some issues with the ignition being a little "sticky". Key has to be just right to get it to engage into operational mode. Key is a bit worn, so just cutting a new one hasn't helped. Is there anything inside the ignition that might affect the light issue? Know an ignition replacement is imminent, but if it will fix both issues, will do so sooner...

Appreciate any help or references anyone can offer!!!