Design Fault on Glee?I have been putting off this report until everything is certain and fixed. But now, all Glee owners should be aware of a fault on my Glee. It is possible that my Glee was not assembled correctly but the Suzuki mechanics who are repairing it under warranty have described the problem as “A design Fault” and are expecting it to occur on other Glees.
THE FAULT
Where the wiring loom is routed under the rear of the tank at the left side, just in front of the battery, fusebox etc., the wires pass over a slighty sharp corner of the frame and have been chafing against it. This has resulted in five small wires having the insulation rubbed off at the underside until they are bare and shorting out. (this happened at about 13,000 miles)
THE SOLUTION
Suzuki has agreed to replace the entire wiring loom (and battery in this case). The dealer has already decided to add a small plastic guard on the sharp corner at the PDI of any new Glees to prevent the chafing from happening – I don’t know if there are any plans to do this at any other dealers or to any other Glees which are already in service. Suzuki took a bloody long time to supply the new loom, it is being fitted today.
THE SYMPTOMS
I will describe the symptoms my Glee suffered, but it occurs to me that the symptoms could be completely different depending on which wires short out and to where they short out.
My problem first occurred when I washed the bike, took it for a five minute “blow dry” ride then put it away. I went back the next morning and it’s battery was completely dead – not just a little bit flat – completely dead. I took the battery out and fully recharged it, during this time the faulty part had obviously dried out and the bike started but misfired and showed an FI for the oil pressure sensor. The dealer collected it to repair under warranty.
The dealer checked all the connector blocks and sprayed all the connectors, but by this time the bike was running perfectly so they returned it to me.
About a week later I took the bike out and it immediately started to rain heavily, within a few hundred yards of riding in the rain the Glee started to misfire really badly and I just managed to ride it home and put it away again. Next morning a completely dead battery once more.
The dealer then started tearing the thing down to find the fault and eventually discovered the bared wires. To see them you have to take the little black side panel off the left side, put your head on the footpeg and look up with a torch.
THE GOOD NEWS
The fault is very easily and cheaply prevented by protecting the wires where they run over the edge of the frame. A little bit of tape or plastic or maybe a well placed wire tie will sort it out.
