Alright, here's the latest update...
A few months back I had already removed the bullet connectors and soldered the connections. I double checked them today and everything looks good.
I checked the voltages coming out of the R/R, I'm getting 13.5v at idle, 13.56v at 3500rpm. However I don't ever see the lights brighten while sitting at idle or even while revving the engine..it seems to only happen when riding, which is odd.
I did re-locate my R/R this evening, didn't have a drillbit long enough so I had to remove the battery box. Overall a hassle, but not a big deal. R/R was moved to the usual spot folks seem to mount it at. I took her for a ride after hooking everything up and noticed everything was brighter about 80% of the time.
I thought to rev the engine a bit to see if it was tied to RPM and a strange new symptom occurred.. In gear (3rd or 4th) I pulled in the clutch and revved the engine. The RPM needle went haywire - up down up down, going as low as 0 RPM and up to 4-5k RPM and back down a few times a second. The engine itself just sounded odd, almost like a car engine that has an RPM cap on it when being revved, but not quite.
The electrical seemed to flicker while this was going on as well. I also tried giving it a lot of throttle with the clutch out and in 3rd/4th..same thing happened which scared the **** out of me (felt like I was gonna lose control) so I didn't do that again.
I'm completely stumped. It sounds like my voltages are a bit low coming out of the R/R, but I was thinking that's just my stator? I've been planning to replace that in the fall when I pull the engine. Could a bad R/R cause this new symptom as well?
Any suggestions on safely checking the voltage while riding?