Oil light issue
This problem has been going on for some time now. If anyone has any thoughts on the issue and how to fix it I would appreciate your input.
2012 DL 650 Adventure - 30,000 miles
Oil light began flickering, checked the oil level through the sight glass and it was good. Obviously I was concerned, but there were no obvious, strange noises and the bike was running great. This began with minimal flickering at speed, then at low speed, low RPM's. It got increasingly worse to the point the light stayed on all of the time.
I took the rubber boot off of the oil pressure sensor and found that the ground wire had come off. No idea where the small screw went, it wasn't inside of the rubber boot. Found a screw that fit, put the wire back on and wallah! All good - but wait.... after 100 miles or so the whole problem began again. Oil light flickering, eventually, the light went solid after 50 or so miles.
I then changed the oil pressure sensor, changed the oil and oil filter. Initially, no light, then the whole thing started over again. Flickering etc...
I took the bike to a local mechanic, he checked the oil pressure and said it was in normal specs. He put on a new Suzuki OEM oil pressure sensor and the same thing happened, no light, to flicker to near solid.
I asked him to replace the ground wire from the sensor to the ECU. Wallah! Finally! No light - for 300 miles!!!! Then, I took off on a 2 week, 4,000 mile ride. Within 100 miles of leaving home the same crap started AGAIN!!!! It happened the entire two weeks I was on the trip, sometimes at low rpm, sometimes only at 6,000 rpm, sometimes only around 4,000 rpm. The problem did disappear for three straight days while I was riding in cooler temperatures but then began again, while still in cooler ambient temperatures.
Some thoughts are - 1) the ground wire is losing its insulation due to heat and occasionally grounding on the engine. (my mechanic did not run the wire through a rubber conduit up to the ECM)
2) possibly the instrument panel simply has a short in it? The fuel gauge is faulty in that the digital gauge sometimes just pulses across the screen as opposed to giving the proper reading of the amount of fuel remaining in the tank. Could the oil light just simply be giving a bad reading as well??
The bike runs like a top and this problem has been going on for almost 5,000 miles now. It's clearly not an actual pressure issue. If it was, the engine would have been long gone by now. I'm perplexed, my mechanic is perplexed, everyone I've talked to is perplexed. Anyone have any thoughts???