V-Strom Wiring projects

Sources:
http://www.vstrom.info/Smf/index.php?
PHPSESSID=48b5319323ff43475266366e573902fa&topic=4523.0
Basic Strom Wiring 101 (DL1000 & DL650)
1. Most wires that are solid Orange or Orange with a color strip is a Switched 12 Volt
wire. However, there are a few Orange with stripe wires you do not what to use. Stay
away from the Orange/White, Orange/Black & Orange/Red wires, these are still
switched power but not ones to mess with. Switched 12 Volt means the wire is HOT
when the key is ON. The reason for using switched power to power accessories, is if
an accessory is left on unintentionally it won't drain your battery.
2. Any wire that is Black with a White strip is a Ground wire. You will find many small
rectangular connectors with 5 or 6 Black/White wires running into them around the
bike. These are ground connection terminals and do not plug into anything. Dont use
these as grounding points for accessories. Photos:
http://www.vstrom.info/Smf/index.php/topic,3825.0.html
3. Best places to obtain Switched 12 Volt power for an Auxiliary Fuse Block Relay.
A. Tail Light wire. This is the Brown wire running in the tail harness along the left rear
subframe. After the tail harness connector (located at the rear of the subframe) it is the
Graywire. Note: This wire is HOT when the key is in the PARK or ON position. This is
good to use if you what to run accessories without having the ignition & lights on. But, if
in park for an emergency and using emergency flashers your accessories will be
energized. This is my favorite, but I also install a small underseat switch to disable the
aux box when desired. Brown wire also avail under fuse box 05 & up 1000 & all 650.
Eastern Beaver Kit.
B. OEM heated grip connector. Located behind radiator on left side & usually taped to
the main harness. A Black connector with 2 wires going to it. Orange/Green wire is
Swithed Hot and Black/White is Ground. If you do not want to cut this connector, then
order Suzuki part no. 36852-06G00 (~ $11). This is the horn lead wire and the
connector will mate. Eastern Beaver Kit.
C. Rear Brake Light Switch wire. Located just forward of the battery. A small clear
white 2 wire connector, one Orange/Green & one White/Black. Orange/Green wire is
switched Hot, no ground wire available here. Eastern Beaver Kit.
D. Instrument Panel Power wires. Located inside left side cowling in wire pocket. Must
remove cowling panel and strip part of harness cover off for wire access. The
Orange/Green wire is switched & the red/white wire is full time power.
E. Any of the Orange (or striped Orange) wires under the OEM fuse box. You can just
detach and pull the fuse box up to gain access. The Brown tail light wire is also here on
05 & up 1000 & all 650.
4. Tail Section wire colors. First listed color will be as it is in the tail harness running
along the left rear subframe. The Second color is after the connector located at the rear
end of the subframe (this is the part that actually connects to the lights).

A. Tail Light Brown & then Gray

B. Stop Light White/Black & then White/Black
C. Left Turn Black & then Black
D. Right Turn Light Green & then Light Green
E. License - Brown & then Gray (Same as Tail)
F. Ground - Black/White & then Black/White
5. Headlight Wires. First color listed is as they are after the fuse and in the forward
section. The second color is from the handlebar switch to the fuse.
A. High Beam - Yellow from fuse to light. Yellow/Blue from switch to fuse.
B. Low Beam - Black/Blue from fuse to light. White/Blue from switch to fuse.
6. Other wires that may be of use.
A. Tachometer signal Brown/Black wire in main harness running through left side
cowling (needed for Cruise Control or Datatool Digi Gear).
B. Speed signal from Speed Sensor Pink/White wire in main harness running
through left side cowling (needed for Cruise Control, Pro Oiler or Datatool Digi Gear).
C. Blinker signal (power) to control switch. Light Blue wire located under OEM fuse
box.
D. Gear Position Sensor signal (going to ECU) Pink wire in 3 wire connector just
forward of fuse box on the 1000 & behind the left main frame above foot peg on 650.
E. Neutral Light Signal - Blue/Black wire in main harness running through left side
cowling (needed for Datatool Digi Gear).
7. Grounding point for accessories. All ground leads should run back to the battery
negative terminal. Either directly or through an Aux Grounding block or Aux Fuse Block
that also contains grounding terminals. The Ground Block, whichever kind, should be
connected to the battery negative terminal with a 10 gage or 12 gage wire. One last
method for a ground buss if you dont wish to use blocks, is to have a short 10 gage
lead running from the battery to which you solder all of the smaller ground leads from
accessories and cover with tape or shrink tubing.
8. How to install a Manual Fan Override switch. Attach a 2 position (On/Off) toggle or
rocker switch across the 2 wires running into the thermostatic fan switch (both
Black/Red), located on the rear-right side of the radiator. Do not cut wires from the
thermostatic switch or the auto fan mode will be disabled.
9. Wiring Auxiliary Driving lights. Most come with a lighting relay and a relay must be
used. Use at least 16 gage (14 gage is better) wire for both power & ground leads. An
On/Off switch, High beam, Low beam or switched power on (not recommended) may
latch the relay. Hot lead must be fused when coming directly from the battery or fused
through an Aux fuse box.
Related thread: http://www.vstrom.info/Smf/index.php/topic,4523.0.html
10. Wiring Auxiliary Horns. It is highly recommended to use a horn or lighting relay for
power to the horns. This relay should be latched using the wires that feed the OEM
horn. Use at least 16 gage (14 gage is better) wire for both power & ground leads. Hot
lead must be fused when coming directly from the battery or fused through an Aux fuse
box. The popular Stebel air horn requires a 15 amp fuse.
Related thread: http://www.vstrom.info/Smf/index.php/topic,1496.0.html

11. Strom Wattage Available. This is at 5000 RPM, at idle and slow speeds,
considerably less.
02 DL1000 = (350 watts) ~95 watts to play with
03 & Up DL1000 = (400 watts) ~ 145 watts to play with
04-07 DL650 = (375 watts) ~ 120 watts to play with (ABS models somewhat less)
08 & Up DL650 = (400 watts) ~ 145 watts to play with (ABS models somewhat less)
02 DL1000 with 05 SV1000 engine & HID headlights & LED's ~ 190 to play with Grin
12. Fuse Sizing for auxiliary equipment. A device is fused properly when the fuse
rating is 150% of the max the fused device will draw. Example: Vest using 45 watts:
I=P/E; I=45/12.5=3.6 amps. So 150% = 5.4 amps, a 5 amp fuse should be close
enough. A lot of devices have an initial surge startup current that is higher than their
steady state draw. Also a fuse that is operated very close to it's rated value can heat up
over time and blow.
13. Connector & wire connections.
A. Connectors. The best way to connect wires to pins for inserting into connector plugs
& sockets is to use the correct crimper for the pins you are using. This is an
inexpensive CRIMPER that works for about 95% of the pins out there. Pins can also be
soldered if you use the proper equipment and techniques. Incorrect technique can
result in broken wires. For most of the people out there it is best to crimp. Crimp style
spade lugs for wires are fine as long as they are crimped & sized properly.
B. Connecting wires. I do not recommend any crimp style connections for wires, except
spade lug terminals for power blocks. Especially the crimp on wire splices. These wire
splices will cut some strains of the wire and let the contaminates in. Wire connections &
splices that are soldered and covered with either shrink tubing or a good grade of
electrical tape, such as 3M Super 33+, will stand up to the weather and vibrations
many times longer then crimp style connectors. Soldered connections will also produce
a cleaner (as in not electrical noisy) electrical connection with less voltage drop. This is
a good HOW TO SOLDER web site. It doesn't talk about wiring here but the technique
is the same. If you can't solder I highly recommend Posi-Lock Connectors , avail at
Walmart & auto stores.
C. The use of dielectric grease on all non water-resistant connectors is recommended.
14. Wire sizing: http://www.vstrom.info/Smf/index.php/topic,2645.0.html
Wire Sizing (Amp Capacity)
First number is wire gage, second is amp capacity when single wire near no other
wires & third is amp capacity when in a wire bundle or conduit.

Wire Size Single Bundled

24 gage
3
2
22 gage
7
4
20 gage
11
6
18 gage
15
10
16 gage
22
12
14 gage
32
17
12 gage
41
23
10 gage
55
33
Don't forget these are max capacities. To prevent excessive voltage drops, use wire
that is double the capacity you require and keep runs as short as possible. Remember
that your wire run is two-way, power & ground.
Wire size chart: http://www.powerstream.com/Wire_Size.htm
Here's a good wire resistance & voltage drop calculator: http://www.stealth316.com/2wire-resistance.htm
Aux Fuse Box Wiring - 101

If using the optional key off power outlet, make sure your relay has an 87 pin and an
87a pin. There are relays out there that have two 87 pins. This double 87 pin type relay
will have power on both 87 pins only when the relay is energized.

Driving Light Wiring with Auto Hi-Beam ON - 101

If you what them to only come on when the high beam is on, don't connect a switch
in the circuit & the diode is not needed, connect the yellow high beam wire directly to
relay.

Headlight Switches Wire Colours

On the right, Y/W on both sides and O on one side to O/R on the other. On the right,
Y/W, Y, W, on one side corresponding to Y/W, Y/Bl, W/Bl on the other. Install a
headlight relay kit to take to load off those connections and the main connector in the
fairing and they will no longer be overtaxed. You'll get more light too.
http://www.easternbeaver.com/Main/Bike_Specific/VStrom/body_vstrom.html#h4dual
Eastern Beaver is in Japan and shipping may take a little extra time due to the
emergency there. If you have the requisite electrical experience, you can add your own
low beam and high beam relays.
Horns

10 amp fuse here. Will need 15 amp for air horn.