Wiring meltdown under tank
Its become very apparent through searching the web that theres an emerging problem with the 2012 model year, and a particular area of the electrical system. Below the seat, on the left side of the bike, theres a huge wiring harness that sits directly on a ridge of the frame.
At 21,000mi, my harness experienced a major failure and has at least 5 wires that have melted together. This is particularly troubling due to the close proximity to the fuel supply line, fuel tank, fuel vapor, and any fuel that may accidentally run down the side of the tank when filling should a overfill or fuel pump surge occurred.
I rode 360mi during this last weekend and had a blast. Everything on the bike worked flawlessly. Upon my return, I washed the bike, toweled it off, and put it away, something Ive done many times. In the morning, I opened the garage to find the marker lights and tail light illuminated without the key being in the ignition. It should be further noted that the ignition was indeed in the 'OFF' position. Im aware of the 'P' position that will illuminate the marker and tail lights with the key removed. This was not the case.
We began investigating the problem by going across all components of the bike and finding no connection issues. We then explored various relays and fuses, checking to see if something had come lose, or had water in it. Everything checked out and we continued going over other parts. As we checked the wiring harnesses, we found the tail light 'browned out' when the harness was moved to the left of the air box region. An immediate burning smell was noticed and we disconnected the battery. As we unwrapped the harness, we immediately felt hot spots in the bundle and hand an entire series of wires melted together. Further examination revealed that a ridge in the frame of the bike, directly beneath the bundle had eaten away to the point of failure. Thankfully we got the power off before a fire had occurred. It wouldn't have been long as the harness quickly heated and was fusing components together.
With the battery disconnected and melted wires fused together, there was nothing left to do. We found the smoking gun that had stumped everyone involved for the last week. Im now working with Suzuki and the dealership to correct this issue.
ID LOVE TO HAVE PHOTOS OF THE DAMAGE, BUT STROMTROOPER SAYS I CANT SINCE IM NEW.