Join Date: Jun 2006
Location: Bryant, Arkansas
And you know your stator is good? Don't remember what you checked in the past.
It could be a junction box issue. Have you looked at it? With the bike running, have you tried jumping power to the + wire going to the headlight? If there is a problem with the relay in the junction box, then the hedlight will come on then go back off. If the relay is working, then the headlight will come on and stay on. You only have to tough power to the + wire going to the headlight for a second. The relay uses feedback loop to keep itself turned on.
If you do that, and the headlight stays on, it most likely is your stator not putting out enough to turn the headlight on. One of the stator's wires is hooked into the headlight relay, and stator rotation turns the headlight on. The headlight indicator being off while the headlight isn't functioning is a good indication of stator issues.
But then, it could be a bad ground somewhere.
$65 leather saddle bags
25,000+ original owner miles