Motorcycle Repair: Ignition switch delay?, suzuki gsx600f, mid life crisis

Question
Mark,

Still no luck with this problem (see below)! I've been fiddling a lot more and have some more symptoms:

If I turn the lights off, the ignition lights on the dashboard come on straight away (stupid me didn't try this before as I constantly leave the switch turned on).
If I then flick the light switch to headlamps:
 - the lights don't come on,
 - the ignition lights on the dash go out,
 - there is a click from the relay next to the fuse box
 - there is a very slight fizz from the battery.

I've pulled the headlamp fuse, and the problem goes away as there is no power in the light circuit, but if I switch on the main beam (different fuse), the problem is back.

Switching on the sidelight or pulling the front brake can also cause the ignition lights on the dash to go out, although not always.

With the lights off, the bike starts without any problem, but if I switch the lights on, it dies immediately.

I've replaced the battery with a new one, but still the same.

I haven't dismantled the ignition switch itself, but I have tested the switch circuits from the connector under the fuel tank, and all seems well.

None of the fuses have blown (which surprises me!).

Any ideas? If it helps I can supply an electronic version of the wiring diagram in my workshop manual.

I could be showing my ignorance here, as I'm guessing the CDI/TCI you refer to is what I know as the ICU - Ignition Control Unit? Without taking it to a workshop and paying for diagnoses I don't have access to a good unit, so are there any tests I can do before I have to take this option (money being tight after Xmas)

Anything you can think of to help track this problem down would be gratefully appreciated. This is my first bike (mid-life crisis), I've not had it long and I'm really missing it (despite the bad weather!).

Thanks

Paul (WYGIGS)

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Followup To
Question -
Hi,

I have a Suzuki GSX600F (1999), which I've had for 2 months. It initially had a weak battery which I fully charged and not had any more problems.

However, I have started getting a problem when switching the bike on with the key in that there is nothing or a delay of up to 10 seconds before anything happens (lights come on etc). I'm wondering if this is anything to do with the wet weather, or possibly a relay somewhere on it's way out? I initially thought it was a bad connection somewhere, but the problem only seems to happen when the bike is switched on.
Any advice would be appreciated.

Answer -
Hi Wygigs,

I suspect corrosion within the ignition switch, or in that circuit's wiring. Maybe a multi-connector is dirty or corroded.

Try dielectric grease in all connectors. Helps prevent water shorting and corrosion.

If up to the task, disassemble the ignition switch and invetigate for evidence of corrosion, etc...

No relays... maybe a CDI (TCI) unit going South, but unsure. Have to perform several checks to diagnose systems. Check Suzuki CDI's with a known good unit. Yup! : )


Respectfully,
Mark Shively  

Answer
Paul,

You need to have a tech check the wiring. I'm certain that a short needs to be located and repaired. You'll have to determine if the short is a bare wire, corrosion, burned or corroded switch contacts, loose chasis ground, etc... It may come down to checking continuity of each length of conductor between connectors.

I would like to have a copy of the wiring diagram for future reference, though it will not help me help you with this problem. Reason being, printed diagram is perfect.

A tech should quickly find the short. Just have to be there with the MC.

Try disconnecting affected circuit components one at a time in attempt to isolate the source. Meaning, disconnect a turn signal and check ignition and light switch operation. next disconnect headlight and work ignition sw., an so on.

You're doing well. I have confidence that you will find the source. And then, the feeling is wonderful.

My email address is: mshively1@woh.rr.com

Mark