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Discussion Starter #1
I have looked over all the threads and am not sure if I can find an answer.

Problem is intermittent. About a month ago had some heavy rains rode bike to work sat in rain for about 4 hrs went to leave work that night no headlights. next day lights worked fine. Figured dried out or something. No problems for little over a month.

No rain or anything now lights are not working again.

I had a issue a while back with the yellow box all the grounds go into where I was getting no power to front of bike and no fuel pump, fixed that and haven't had any problems since with priming issues.

All fuses check fine. Can a relay slowly go out? for instance work for a while then not then work again then not?

Any suggestions will be of great help.
 

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Discussion Starter #3
Thanks Dcope, def knew about that issue I had checked there recently when I had the yellow box problem, also when I had a light blow out and it was shorting out and blowing a fuse. I'll open it again today to see if maybe my time has come for that little thing to rattle loose.

Just a (what if) but if it hasnt should I be leaning toward relay issues?
 

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The low beam doesn't use a relay, so if you're having problems with both, either the switch or something else. If its high beam only, then possibly the relay.
 

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Discussion Starter #5
Ok opened the switch and all wires were solid and connected.

Interesting what you said too about the low beam not being on a relay, because a symptom initially was when I would start the bike the lights low and high would click off for a moment then I would hear a click and it would come back on, did for some time figured if they are working they are working. This is why I assumed there was a relay for some reason on the low beam as well. So now the prob is sometimes the lights work then I start the bike and then no lights at all even if I ride around for a bit, but then sometimes they are working fine??

What now if the switch looks fine, pinch wire maybe? something with the headlights? just a connection i should check somewhere maybe a little loose, what would I look for?

Appreciate your help Dcope, thank you.
 

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if that's not it... prolly the start button. When you start the bike, the lights shut off while holding the starter button, then come back on when you let off the start button. If that button doesn't come all the way back out, the lights will stay off.
So next time it happens, pull out on the starter button. Don't clean that button now, wait till it acts up again, That way, if pulling out the button fixes it, that was the problem. If that doesn't work, then you know your problem is somewhere else.
 

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Discussion Starter #7
Ill try that today if it happens again, I went and turned it on twice after I checked the wires and its working fine right now. Of coarse it seems to happen a night. hopefully the button is just sticking a little. If so just grease a little or something?
 

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Discussion Starter #8
So the dang thing has not had any problems since the last time I guess I'll just have to wait for it then fix, thanks again for the help. Maybe the fiddling with the switch worked out some hang up.
 

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Oh man. Thanks for this thread. I thought I was the only one. My bike went through the same way. Here's my thread: http://www.600rr.net/vb/showthread.php?t=174389.

I still couldn't figure it out either. At first I thought it's the rain, then it died on me yesterday. Dcope may be right about the starter switch is not being pulled out completely. I'll keep an eye on that.

I also want to add that when you turn your key to the "ON" position, usually, you'll see the blue high beam indicator flashes. This will ensure the headlights turned on correctly. When the blue indicator is not on, in result, my headlights not functional. This led me to believe that the Headlight Relay maybe faulty. The electrical diagram can confirm the relay connection. The red wire runs from the relay to the high beam and then to the low beam. I guess that's the ground connection (I can't see) - someone else confirm? I wanted to replace the relay, but don't know where it's located. :banghead:

I hope both of us can figure this out.
 

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I just remembered cbr600rayray mentioned about how the light will not go on when it's too tight. I've also been through that. After opening up the Start Switch Housing, I tried not to over tighten the screws. It would work when I let it loose and would not when I screw it on tightly. I'm not sure what the deal is with that.
 

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Discussion Starter #11
I put di electric grease on the starter switch points, just a dab not to cause cross connection, took bulbs out and were fine, all fuses fine, haven't had prob since the last big rain storms, luckily out here that's not very often, hope yours was worked out dreamz.
 

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We got the weirdest problem with our bike, but hopefully that's the culprit. I can't think of where else it would cause the light to go out. I hope your stays on too...
 

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Discussion Starter #13
Shoot, problem is back and now staying. No headlights yet everything else works, bulbs are fine and starter switch is perfect???
 

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Discussion Starter #14
Dang starter switch!!!! Finally broke itself off. Red wire was disconnected, so many times I've checked there and it wasnt the prob. This time though, yep sure was.
 

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Dreamzboy, given that you both describe the same symptoms it may be worth taking apart your starter switch, high beam switch ect ect and re-flowing all of the joins.
 

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Dreamzboy, given that you both describe the same symptoms it may be worth taking apart your starter switch, high beam switch ect ect and re-flowing all of the joins.
Yeah. That's where I usually check first. This time is was actually the starter switch. It got stuck. I noticed it because I turned off the ignition, turned it back on and pushed the start button and make sure it popped out after my press. It starts right up and all headlights are on. If it doesn't pop ALL THE WAY out, your headlight won't turned on. Make sure to clean it off and put a little bit of grease or oil around it to eliminate the friction. Mine wasn't completely stuck, but if it's barely pushed in is enough for it to cause the headlight not to turn on.
 
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