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Discussion Starter #1
So back to square one. I'm still having a charging issue. I've replaced and moved the R/R. I've replaced the battery (to a nonMF one for now because I will get the warrenty replacement on the MF one) and I've tested the stator and it comes out fine as far as I can tell. The problem is I'm still not holding a charge.

With the bike off I get a charge of 12.6v. With it running it drops to 12.5 but will increase with throttle and by the time I get back from a 10 mile ride (about 20 minutes) it will be down to 12.2volts when I turn the bike off. Is there anything I should be looking for that anyone can think of? I'm sure there's something I'm not catching...

TIA
 

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These readings sound a bit low to me. With the bike rev'd to 2500 what kind of voltage do you get at the battery? and, with the bike rev'd to 5000 what is the voltage?
 

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Discussion Starter #3
To 2500 I'll get 12.6 and 12.8 at 5500.
 

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This is definitely low. You should be seeing around 13.5 @ 2500 and about 14.8 @ 5000. I know you said you tested the stator, but just to have all of the details:

(engine off) what is the resistance on each pair combo of disconnected stator leads?
(engine off) What is the resistance on each lead to ground?
(engine running) what is the AC voltage on each pair combo of disconnected stator leads @ 5000 RPM?
 

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Discussion Starter #5
resistance to each pair of stator leads (off but warmed up) was 0.6 each
Resistance to ground was infin. on all
AC voltage was 70v +-5 on all leads

I wonder if something is staying on or if I have a bad ground somewhere or what.... I really am lost on this.
 

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Well the good news is that the stator sounds fine based on those readings! I would suggest doing a diode test on the RR just to make sure that it is good. After that I would suggest putting a multimeter in line with the battery to check the amps with the bike off. It should be 0. If you are seeing a power draw then you have a problem somewhere in the wiring.

The problem for me though, are the readings at the battery. They are low. So I am guessing either the RR has a problem, or there is an issue in the wiring between the RR and the battery. Have you opened up the loom and traced the wires from the RR to the battery?

Also, as I think about this, I am remembering a bunch of posts recently regarding the brown wire causing some major headaches in the charging system. I think SlimVR was the one. (sorry Slim if I am remembering poorly!)
 

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One more thing...Have you checked/cleaned all of the connections? Dielectric grease after a good cleaning is not a bad idea either. Just thinking out loud here.
 

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This is probably too easy but here goes: there's a white wire with a red stripe that connects the positive pole of the battery to pretty much everything in the bike. In the wire is one of those bullet connectors. It's easy to get to so I'd pull it apart, clean it up and put it back together with some dielectric grease. Then check the voltage at the battery. Might work. Don't cost nuthin.
 

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Discussion Starter #9
I will probably end up pulling the wires apart and doing DG on all of them. The R/R is brand new and tested fine when I got it. I'll have to check the red/white wire as well and see how that it. Man this is such a PITA.
 

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Electrical issues really can be PITA!
 

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Make sure that the connections (the metal to metal parts) are tight. Sometimes the plastic part is snug but the parts inside it are loose. Some members have gone as far as soldering the connections. I woulld do that as a last resort.
 

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Discussion Starter #12
Hmm I'll look into that as well. Working the tail end of a 36hr shift, so It'll be when I get home, so hopefully it works out.
 

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Discussion Starter #13
So I don't know what I did but I know get 13.5 at 2500rpm and 14.something at 5000rpm. It's better then before, so maybe it was a lose connection, but I still lose a charge (if I got on a ride and start at 12.7v it will be 12.5 by the time I get home, even on a long highway ride at 5krpm the whole time.)

Then Last night I get on my bike to ride home, and my headlights out....but it's not the bulb, its the JB again. Switched the blue wire over and it worked fine. But I'm still lost so I have no clue what it could be. The R/R is new and relocated.
 

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My bike has always since day one of my ownership has had the light come on as soon as I turn the key on. As long as the system is charging and the bike starts fine you are okay. imo
 

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The brown wire is a voltage sensing wire. It senses voltage on the white wire circuit, and tells the regulation part of the R/R how much power to deliver to the white wire. It usually makes connection through the ignition switch, so a bad connection in the ignition switch could act as an open circuit. If it were me, I would get the bike running and steady at around 2500rpm, Then I would put a jumper between the white wire and the brown wire on the R/R, and check voltage at the battery to see if I have a charging voltage. Like 14.7 volts or so.
Edit: I would also make sure all the grounds were good on the bike. Especially the one from the frame to the engine.
 
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