Hey guys, I have a 05 CBR 600RR. Been riding perfectly since I got it in February. I noticed sometimes the headlights would go out but they’d come back on. But Thursday, the bike ran fine, ran inside came out and wouldn’t start. Somehow got it running again, and here I am, not running again.

I checked the bank angle sensor, has power, I even tried jumping it and nothing.

I tested my fuses, relays, all good.

Im really stumped now and lost when it comes to electrical.

 

Time to start checking the harness and connectors.

 

My 06 600RR was having the same issue. Turned out to be the kill switch/start switch assembly on the right handlebar. I had read that the headlight issue was caused in there, and I noticed if i smacked it a few times they'd come back on. Then one day the bike wouldn't start.. I flipped the switch back and forth a few times and it finally went. Replaced it several months ago and have not had a problem since.

 

Had the same issue with my 05 600RR. Ended up being where all the grounds come together in the main harness. There is a plastic piece with a metal bit that all the grounds connect to. I cut out the burned up plastic and then soldered the grounds to the metal bit. Taped it up and haven’t had an issue for many years.
The ground is located in the main harness on the sub frame. It’s a little before the tail light and turn signal plugs. If you look at the images of this eBay listing, you’ll see a yellow plastic bit. That is the piece I’m talking about. It burns up not all allowing the circuit to be complete. Cut out the burned up bits and solder the connectors to the metal bit inside, wrap with electrical tape and you’ll be good to go.

2005 2006 HONDA CBR600RR OEM MAIN ENGINE WIRING HARNESS MOTOR WIRE LOOM https://rover.ebay.com/rover/0/0/0?m...2F254275735167

 

Had no start issue...like Shawn809 said, the kill switch can be finicky. Pulled the housing apart, if you look underneath, the solder points on the switch are very minimalistic (not necessarily well soldered and prone to cracking or coming apart). Re-soldered mine and voila.... Bob's your uncle.

Easy check to do. Two screws and you can separate the housing and inspect. Worth a check and maybe even worth a re-solder just to be safe in the future.