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Discussion Starter #1 (Edited)
Before seeking the resolution below, thoroughly check the fuses for the headlights located on the left side of the mid fairing (see image below). This guide is specifically created for 2003-2006 CBR600RR. Newer model bike may or may not applied. Stable hands and soldering experience is required, failure to have this will result in a short on other electrical components.



Problem: Both headlights do not turn on when the key is at the "ON" position or after the engine has started and running. High beam headlight doesn't respond when the high beam button is pressed. On the initial start-up of the gauges, the high beam light indicator is lit, but stayed off.

Cause: Solder point or headlight fuse is broken.

Tools Required:
  • Philip Screw Driver
  • Soldering Iron (Fry's, Radio Shack)
  • Soldering Lead with Flux (Fry's, Radio Shack)
  • Tweezers
  • An additional person to hold the device in place while soldering.
Procedure:

1. Remove the 2 screws located on the bottom of the "start" button housing.





2. Carefully open the housing and unscrew the silver screw.



3. Once the metal plate is removed, check to see if any of the 3 wires are disconnected. Make sure to wiggle the wires to confirm that the connection is solid. It may appeared that the soldering joint are connected, but in fact, it may not. The headlight wire is colored red/black.



4. Next, remove the wire clamp screw (1) along with the screw that hold the "start" button in place (2). Take a careful look at how the wire clamp is assembled, the housing will not snap together if done incorrectly. The plastic tab underneath the metal clap may break off.



5. Carefully remove the "start" button from the housing to expose the electrical component and to ease the job of soldering.





6. Plug in your soldering iron and let it warm up to the operating temperature (2-3 minute). Using an additional hand to hold the button, melt the solder core/lead onto the contact point shown in red and let it cool. Note: if the solder core has flux (solder glue, yellow looking liquid when melted), it will stick very easily without any effort.



7. With one hand holding the headlight wire, while the other holding the soldering iron, melt the solder ball done in step 6 and insert the headlight wire into the liquid solder. Once the connection is secured, pull on the wire to make sure it sticks.

8. Turn the key to "ON" position to see if your headlight turns on. Reverse the steps to reassemble the start switch.


Good Luck! Thanks to DCope17 and a few others for the help.

 

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Discussion Starter #2
One more note on Step 4.

When reassembling the wire clamp, do not over tightening the screw. Doing so will cut off the current going through the wire; hence, sometimes it works and sometimes it doesn't as you move your handle bar around.
 

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This would have helped me when I had this issue. Thanks for helping out the site!!

Though I didn't remove the switch when did mine but I worked on airplanes for awhile so I am used to working in tight spots. I just took off the metal plate thing and soldered from there.
 

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Would this problem also make the plate light go off? Last night I was about to go out and noticed that my headlights and plate light were not working. The instrument cluster was which they share a fuse with was working fine. Just checked all the fuses and they seem fine, but no power to lights/plate light. 3rd eye/signals/tail light work fine. Could this be a likely cause?
 

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Great post! I'm having the same issue with my bike, but now it won't start either :( how long did it take to get that taken care of? I got a tight timeframe today but hopefully can squeeze it in ASAP.
 

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Not right now chief, im in the f'ing zone
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Perfect. This problem pops quite alot here on this forum.
 

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Discussion Starter #7 (Edited)
Great post! I'm having the same issue with my bike, but now it won't start either :( how long did it take to get that taken care of? I got a tight timeframe today but hopefully can squeeze it in ASAP.
It doesn't take long. Just unscrew the ignition housing and all the wires shown should expose to you. You can then test for connectivity and voltage. I just know one of the 3 wires are for headlights, not sure about the other 2.
 

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Discussion Starter #8
Would this problem also make the plate light go off? Last night I was about to go out and noticed that my headlights and plate light were not working. The instrument cluster was which they share a fuse with was working fine. Just checked all the fuses and they seem fine, but no power to lights/plate light. 3rd eye/signals/tail light work fine. Could this be a likely cause?
Test for voltage in your plate light. It could be the light itself is defective. Trace back to where the wire goes and test from there. I just have a feeling you didn't really check all 5-6 fuses in the box.
 

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i have the same problem sure enough this was the problem now to figure on how to solder it lol i bet if i had took it to a bike shop they would of riped me off and said it was something major thats my luck but thanks to you guys that had ideas on my headlights not coming on this was the problem thanks guys you rock
 

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I have a different problem. my headlights wont turn on. BUT if i press the passing trigger the low beam or both for high beam WILL come on depending on which one is selected at the switch. All the fuses are fine. I cant work out what it is?? Any ideas?
 

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hmm...this happens to my wife's on occasion...I was blaming it on my own work as I put relays to run her HID projectors.

Hope this takes care of it...thanks a million!
 

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Great post dreamzboy, thx!
Just went on a breakfast run with 3 other guys, all riding suzukis. All of them flamed me for being the only honda rider ( just joking around). Them my lights went out. Then the real flaming started as a result of the faulty lights. Just got home, found this thread, and sure enough it was the lose solder joint on the started. Fixed it in 30min. Just glad it wasnt something major!

Thx agian dreamboy! Now to go flame some suzuki arsh!
 

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Awesome write up thanks for sharing it
 

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Wow thanks, I was getting so frustrated trying to figure out the cause for this, almost gave up and took it to the shop. But sure enough, my cable was off. Bought a solder iron today and will fix it tomorrow. Thanks again.
 

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Glad I saw this post as well. I was ALMOST tempted to take it to the shop and drop some dough on it. Found this threat, opened up the housing and there it was. Rehooked and soldered and everything worked great!! I also unplugged the headlight relay to try and get it reset as well. GREAT POST!!!!
 
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I've heard about the possible issue, but I've checked and all is well on my handle bar. I've gone threw a pair of main wire harness and a sub harness with both coming up the same way a fried and crispy harness which leaves me to believe there's a short. Has anybody ended up with this issue? oh and it's only my high beam that doesn't work.
 
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