2012 Glee electrical issue

[greywolf]

Also remove the zip tie there and use tape instead. It may be cutting into the loom. I still think it may be a salt water problem so watch for wonky electrics even without shorting to the frame.

[vstroman]

That pic is a great help Hondaman,and thanks to Greywolf as well,I'll remove that cable tie if it's there.

[vstroman]

Have a read here 

http://www.v-strom.co.uk/smf/index.php?topic=16745.0

Thanks, interesting reading.

[UK_Vstrom650]

Got a call today saying the issue is under the seat area. Apparently a metal bracket (?) has cut through the positive/negative wires shorting them out. Are going to solder and shrink wrap to get me back on the road. They've taken pictures to submit a report to Suzuki (I've asked for a copy of the pics), and are recommending they replace the wiring loom. Said it's the second one they've seen. Odd thing though, was they also said if Suzuki were to replace the loom they might not pay for fitting...  very odd, but if that's the case they can give it to me and I'll do it myself.

Will update when I hear back from Suzuki...

[UK_Vstrom650]

Appleyards got back in this afternoon.  Soldered the joint. Put it back together. Went to road test it and noticed the speedo doesn't work (display fully illuminated). Have checked the speed sensor and that's OK.  Did say there's a black tracer wire coming up near where the broken wires were but it doesn't go anywhere and doesn't look broken, but they're trying to chase what it is  looks like another long weekend without the bike as they're not in tomorrow 

Maybe I should just get it back and use my satnav for the speedo until I (MOT is in July so providing I fix by then...  )

[greywolf]

The speedo wire is pink/white. It runs from the sensor at the front sprocket to connector inside the left frame hanger. From there it runs to a connector inside the left cowling. Finally, it runs to the instrument panel.

[CARL.BRIDGES]

  Well I thought I would relay some of my own experiences ! I am now hoping to have mastered the issues the Vstrom 650, 2012 electrics have thrown at me !
Yes first problem frames and main loom rubbing ! Resulting in One side of indicators reaming on until the wire melted , funny burning smell electrics and plastic combination!
Fixed at local dealers in Swansea , fitted a bypass wire and added a rubber strip between frame and loom ! A year later the headlamps fail , pilot lights are OK ! Mechanic at local shop pressed hard on starter , Hello presto it worked it turned out the contact in the kill switch were filthy, cleaned then no problem,  until headlights fail again , this time dealer strips bike , air box off etc.  This revealed the melted connector see photo ! Cleaned and refitted , yes it worked but next day out and about the bike stopped , loose connection under tank ! oops ! They fixed it and off we go OK ? Well no headlights failed again Doh ! So I take the tank off , air box etc. Then find melted connection , bypass this then soak all the connectors and fit inner tube sheaths to them all ! Yes all is now well ! Now I get  a recall from Suzuki about the stator !
Well I love my Vstrom its done 30 thousand miles, but for the life of me why oh why have Suzuki allowed such a good bike to have such failings ? Its a real shame its put my mates of buying one !

[UK_Vstrom650]

Collected my bike on Wednesday. Was supposed to be a couple of hours labour, they said they had over 12 hours in it 

On Friday last week I was told they'd fixed the loom, went to test ride and the speedo wasn't working (display fine, no speed). The speed sensor tested fine so apparently went through the loom again (fine) and eventually borrowed a speed sensor off another bike and apparently it worked. They said they'd have to order one in (£100 from Suzuki & 48hrs delivery time). I said not to bother, collected the bike, bought the right part off ebay for £20 ( to Greywolf for confirming the part!) and 2 minutes later it was working fine again. Went out today for the first time and all seems good.

Have to say I'm not impressed with Suzuki electrics. I was told something like there's a connector inside the main loom that had severed (still awaiting a copy of the pictures I'd asked for) and not overly impressed with 2hrs labour turning into 12hrs. They've said they've submitted a report to Suzuki for a goodwill gesture, but am not confident of any of it. I probably should have done my first instinct and just replaced the loom and saved the time and expense.

They also gave me a quote for a Tracer on PCP (before I went to the workshop and found out the above) which I may have been tempted by if I hadn't just spent a small fortune on this bike in the last 2 months 

If I do get the pictures I'll post them on here so it may help others in future 

[Hugh Mungus]

Hmm, typical. How it has transpired into a 12 hour job astounds me. It shouldn't take anywhere near as long as that.
As you say, maybe a loom replacement would have worked out cheaper 

[greywolf]

I've always hated that Suzuki buries crimp connectors inside the harness. They are subject to water entering and wicking to the connectors, causing corrosion.

[UK_Vstrom650]

Finally received a picture of the offending wires... red, red/white?

There's also a black with green tracer wire that apparently doesn't connect anywhere, neither the dealer nor Suzuki could figure it out but was told it isn't cut & doesn't connect up...

So fixing this (which they found when they first looked at the bike - had sent them the video from earlier in this thread), and diagnosing a faulty speed sensor took 12hrs labour, although they said the sensor passed the factory test so they thought it was a wiring loom issue even though the sensor worked fine before the electrical fault.

And, I've been told Suzuki have rejected a request from the dealer for a goodwill gesture on the grounds they would only do one within a year of the warranty expiring and they would only contribute towards the cost of a new loom, not any labour...  which I couldn't be told until I'd had the work carried out  Think I'll contact them direct but otherwise absolutely no point using dealers after 4 years on a three year warranty or 3 years on a 2 year one.

[greywolf]

A black/light green wire goes from the ECU to a secondary throttle motor.

A black/green wire takes the message from the ECU that all the safety switches are in the proper position. If that message doesn't make it, you get a CHEC on the display panel. Normally, the fuel pump won't run and the starter motor won't spin with a CHEC displayed, but those will work in in this case because the ECU "knows" everything is okay. It just isn't able to let the display "know".