New Generation SV650 Headlights not working

Well they weren't, now they are!

...

Ok, seriously. Thought I'd post so it might help even 1 person who may have similar problems.

Problem started (I thought) in France, when I got off the Ferry and suddenly found I had no headlights/High Beam/Passing button. I stripped the front of the bike down and removed the lights. Bulbs were in perfect nick, and wiring seemed in good condition. Checked the conectors and fuses which seemed ok. So hoped putting everything back together would cure the problem. Nada!

So what was the problem? Problem actually started a while back when I had starter button problems. Dissasembled it, which is not as easy as it looks. Pro tip: make a step by step note of how everything comes out as its a bugger to put back right first time (and I could find no diagrams of the innards of the switch).

The spring working the button had deformed which meant the button was stuck in. When this first occured it was daytime so I didn't notice an issue with the lights. The issue was that the starter motor (or whatever mechanism it was) kept whirring when the clutch was pulled in on the move.

Note: Reference to 'MacGyvering' something is using lateral/creative thinking to solve a problem. See Wikipedia for more details

So I Macgyvered a solution by breaking an old gadget and re-using a spring which was much thicker than OEM. I then realised what Suzuki budget build quality was - rubbish. They could have come up with so many better solutions that wouldn't cost that much. More importantly, it wouldn't casue a problem for the rider!

Anyway. It seems that over time, even this spring wasn't sturdy enough and the problem slowly came back. Only, when the lights failed in France I didn't think to check the ignition switch.

Back in the UK, I stripped the bike down a bit, checked the run of the wiring, re-checked the bulbs, checked the battery connections, checked the fuses, checked the connectors, cleaned everything and re-assembled. Nada! Grrrrrrrr

As an afterthough, as it was on my list of little jobs to complete, I checked the spring and MacGyvered a more permanent solution. Re-assembled and presto! I had lights. Credit must go to the 1 post in 100 that mentioned that the ignition connection sometimes fails which disrupts the circuit that allows the headlights to work. The insightful bit was explaining why the headlights wouldn't work but all the other lights would, because they are on a different circuit.

This had caused numerous red herrings. In the end the solution was a 5 minute one, compared to the four hours it took for me to dissassemble, check and re-assemble all the bits and peices related to the electrics.

So, if you're having problems with your ignition switch, it may lead to other unintended problems with your bike including the lights.

[Bibio]

your only supposed to press the button with your thumb not try to shove it to the other side of the controls

and yes the starter circuit on the later bikes (from K4) cut the headlight while starting.

how many miles has your bike done and do you keep it outside?

Haha! That's about right. Its all my years of video game button bashing you see. You also win the perception prize. From new(ish) I've done close to 15k miles in just over 18 months. The bike generally lives outside but mostly covered. Therefore, although it does tend to get a bit dirty, this is mostly through the amount of riding I do.

[Bibio]

that's pretty bad giving up like that after only 15k.

[Toooldtodie]

Thank God for the SV community! Just had same thing happen to me. Do not have skill or time to do myself, but have given the garage these findings to check first. Might save me much pesos. Many thanks Runako, your post is a welcome steer as to what may be wrong with my bike. Will update this thread if found to be something else.

No problem. If it helps one other person then its useful and I'm happy Hope you get it sorted fella.

Thanks for this post I THINK I might have figured out my problem. Now to investigate further tomorrow morning. bumping in case anyone new hadn't seen this.

I checked. It was indeed the ignition switch. If i press it slightly to the left with my thumb it lights up. I have a feeling the bikes vibration alone will be enough to turn them off constantly so will need to open that lil box up and take a look. Jam things around a bit until they work.

Had this issue 2 weeks ago on my 2014 SV650S L2. Lights only worked when I pressed it with pressure to the right. opened it up and found the button has a contact on its left side that was stuck in, pressed it a couple of times to free it and it was back to rebounding correctly again. The longest time was spent putting it back together, the other larger spring behind the button is a nightmare to put back in.

I had this, stripped mine & cleaned it all out - worked fine for a week then back to square 1 - fitted a 2nd hand switch and all good (for now).