Wiring meltdown under tank - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 30 Old 03-21-2015, 06:28 PM Thread Starter
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Exclamation 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.
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post #2 of 30 Old 03-21-2015, 06:36 PM
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Upload to IMGUR and post a link to there?
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post #3 of 30 Old 03-21-2015, 06:44 PM
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Sorry to hear about that, you seemed to have copped a severe instance of this problem.

You're quite correct about the propensity for it. Being the cynical guy I am, I googled "problems DL650 L2" as soon as I got the bike and this popped up a lot. Fortunately it gave me the opportunity to do some protection/modification to that point on the harness early on, otherwise I would have been in line for the same problem as you...

Warranty, or too late?

"Between two evils, I'll always take the one I've never tried before..."

Shiro Nakama #069

Suzuki: RF900 x 2, DRZ400E, DL650L2 ABS(sold), SV650SK9 ABS
Honda: CB750F2, VFR750/RC36 x 2, VTR1000 x 2
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post #4 of 30 Old 03-21-2015, 07:11 PM
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I think that is the first case I've read about outside of England. Do you ride with salt on the roads by any chance? My theory is salt water gets into harness and corrosion in a crimp connection causes overheating. That melts insulation which leads to shorting on that frame member. The Wee has the harness passing over the frame in the same manner and doesn't have the problem. V-Strom Owners Club UK € View topic - A warning to all Glee owners please read!!!
I've glued a piece of plastic between the harness and the frame just in case.



Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

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post #5 of 30 Old 03-21-2015, 09:10 PM
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Would this apply to the 2013 as well?

-Gary
2014 V-Strom 1000 - Desert Khaki
2016 GSX-S1000FA
2012 DR650SE
2011 Burgman 400
2007 Honda Helix
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post #6 of 30 Old 03-21-2015, 10:26 PM
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All Glees are identical in that area.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #7 of 30 Old 03-21-2015, 11:02 PM
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I looked under the seat but just not seeing it. Any pictures or descriptions to pinpoint the location? Do you have to take fairings off for access?

-Gary
2014 V-Strom 1000 - Desert Khaki
2016 GSX-S1000FA
2012 DR650SE
2011 Burgman 400
2007 Honda Helix
2013 V-Strom 650 - sold
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post #8 of 30 Old 03-21-2015, 11:15 PM
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Look at the worn spot in the top picture. It's directly above the chain. Reach up to find the aluminum part and up higher to find the wiring harness which was removed to take the top picture. It's right under the rear of the tank.


Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #9 of 30 Old 03-22-2015, 04:51 AM
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As per GW's pic... I also mounted some high density foam to protect from the sharp edge threatening the harness. Only removed seat. I don't think I'd've needed salt to create a problem, over time..

"Between two evils, I'll always take the one I've never tried before..."

Shiro Nakama #069

Suzuki: RF900 x 2, DRZ400E, DL650L2 ABS(sold), SV650SK9 ABS
Honda: CB750F2, VFR750/RC36 x 2, VTR1000 x 2
Yamaha: GTMX80, MX125, Virago250, Virago1100

Last edited by Zone5; 03-22-2015 at 05:03 AM.
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post #10 of 30 Old 03-22-2015, 10:33 AM
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I couldn't feel anything sharp or raspy there and the harness doesn't move. Sticking some plastic or rubber in there is easy though.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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