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Join Date: Jun 2006
Location: Corpus Christi, Texas
The Vulcan shares this charging system with several Yamaha models so it's not just Kaw. Electrical problems are always a pain to deal with but deal with them you must or the bike won't run. In comparison to some of the Hondas I've worked on, this one is fairly straight forward.
Have you checked out Electrosport's troubleshooting page? It will list the steps to go through to check the entire charging system.
BTW, 12v at idle is a bit low but in spec. The question is, how much at 3k or so? I've missed something so I don't know what the white wire issue is. If it's like mine, it gets VERY HOT and melts the insulation. Chances are the R/R is way out of spec and will fail soon. Mine did. In measuring resistances, I found the stator to be partially shorted but functional. I opted to replace it as it will continue to get worse, not better and I'd really rather only replace the R/R once than have the stator take the new one with it when it fails.
93 VN 750 "Ursula"
Moved R/R 08Sep06
R/R rewire 17Feb07
New R/R, Installed 14Jun08
New Stator installed 10 Jun08
Maintenance Free Battery 12Jan08