I am writing in on behalf of my son and his 2002 TL 1000R which has 30k on the clock. We have had a few issues that we have addressed as in the starter button.....taking it apart and sanding the contacts....repaired! Well the latest thing is that the headlights are not coming on when trying to start the bike.....they always came on before. Flipping the high low beam switch does nothing too. We checked both lights and they are okay...no opens. We checked all the fuses too and they are fine also. I know that the suzuki's are notorious about their electrical switches. I put the meter on the connector that connects to the lights and got no voltage on either wire(high and low beams). I am asking because maybe one of you has had the same issue. Thanks for any and all responses.

Russ

if you get no voltage at the headlight connector (where the bulb plugs in) keep going back further and further until you get voltage. Then you problem is between those 2 points.

Once you pass the fuse box - it would be helpful to have a wiring diagram.

The contacts in the switch should have been cleaned with a pencil eraser - sanding it makes the contact plate thinner (even a little bit) - increasing the distance between the 2 points to make contact = no contact = no voltage at the bulb connector.

if you get no voltage at the headlight connector (where the bulb plugs in) keep going back further and further until you get voltage. Then you problem is between those 2 points.

Once you pass the fuse box - it would be helpful to have a wiring diagram.

The contacts in the switch should have been cleaned with a pencil eraser - sanding it makes the contact plate thinner (even a little bit) - increasing the distance between the 2 points to make contact = no contact = no voltage at the bulb connector.

if you get no voltage at the headlight connector (where the bulb plugs in) keep going back further and further until you get voltage. Then you problem is between those 2 points.

Once you pass the fuse box - it would be helpful to have a wiring diagram.

The contacts in the switch should have been cleaned with a pencil eraser - sanding it makes the contact plate thinner (even a little bit) - increasing the distance between the 2 points to make contact = no contact = no voltage at the bulb connector.

if you get no voltage at the headlight connector (where the bulb plugs in) keep going back further and further until you get voltage. Then you problem is between those 2 points.

Once you pass the fuse box - it would be helpful to have a wiring diagram.

The contacts in the switch should have been cleaned with a pencil eraser - sanding it makes the contact plate thinner (even a little bit) - increasing the distance between the 2 points to make contact = no contact = no voltage at the bulb connector.

if you get no voltage at the headlight connector (where the bulb plugs in) keep going back further and further until you get voltage. Then you problem is between those 2 points.

Once you pass the fuse box - it would be helpful to have a wiring diagram.

The contacts in the switch should have been cleaned with a pencil eraser - sanding it makes the contact plate thinner (even a little bit) - increasing the distance between the 2 points to make contact = no contact = no voltage at the bulb connector.

if you get no voltage at the headlight connector (where the bulb plugs in) keep going back further and further until you get voltage. Then you problem is between those 2 points.

Once you pass the fuse box - it would be helpful to have a wiring diagram.

The contacts in the switch should have been cleaned with a pencil eraser - sanding it makes the contact plate thinner (even a little bit) - increasing the distance between the 2 points to make contact = no contact = no voltage at the bulb connector.

WOW - epic site error :dunno

Ya think???

If the starter button acts up again then we will likely replace it......

oh i thought this was about headlights not coming on. The solder points in the switch housing can get really hot and come loose - may want to open the headlight switch housing and check the copper contact plate in there....it'll be just like the starter button.

Just a follow-up on this issue........my son did not want to tear the bike apart. He ended up bringing it to the shop and they found the issue under the tank one of the harness connectors was burnt out or something......they cut all the wires and replaced it with about 15 wires going to it........$180 later and he is all set. Thanks for the comments and advice.