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Discussion Starter #1
Lately my bike wouldn't crank after riding for a while. I figured out that the battery was slowly dying while I ride. I replaced the RR. I also know that my stator is good. Battery is good too. At the RR I get 13.3v at idle. At the battery I get about 12.8v. I am getting .5v voltage drop between the RR and battery. Looking at a fault finding diagram I see that I should only be getting .2v or less. Even from the RR to the ignition plug I am losing about .3v. I have checked over every inch of the wiring. There are no bad connections or frayed wires. The closer to the RR I check the voltage, the closer to 13.3v it is, but as I get farther from the RR and closer to the battery, it gets lower than 13.3v. The wires going from the RR to the battery do get pretty warm to the touch. Should I replace the wiring with a thicker gauge, or are there some other things I should check first? I modded 2 H7 dual filament bulbs in last year. If I ride with the low beams on the battery will stay charged. If I ride with the high beams on the battery will slowly go down as I ride. I haven't unplugged the headlights yet to see if that is causing my problem.

I get no voltage drop from the RR ground to the battery ground.
 

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Discussion Starter #3 (Edited)
Everything checks out. The stator has 0 resistance. There is no continuity between the stator and bike ground. There is no amp draw. The charging system is putting out like it should be. The problem is that the voltage is dropping .5v before reaching the battery. At idle the stator puts out 22 - 23 AC. At 5,000 it jumps into the 50s AC which is within spec.

I have the manual on my computer. I've tested everything it showed.

According to this chart I have a bad connection between the regulator and the battery, but there are no bad connections.

http://www.electrosport.com/media/pdf/fault-finding-diagram.pdf
 

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Hey did you ever find the solution to your problem? I'm having a similar issue, my stator shows some readings when I test it to the battery ground. I feel like my stator is the problem and its just a matter of it being wired incorrectly but I don't have a service manual to check the diagrams

I just got my stator cover painted by my friend and the problem started after that with my battery not charging. When I check the voltage coming out of the stator at idle its up around 30v. I haven't tried all those tests on the flowchart you have the link to.

I'll try that tonight, thanks for any tips.


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Discussion Starter #5
I never found a solution to the problem. If I ride with the low beams on then my battery stays charged enough to always crank back up.
 

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I actually figured out what my problem was.

Seems like the previews owner had replaced the stator cover and he cut the 3 yellow cables that are connected to the stator (no idea why) he did a crappy job taping them back together. So the oil over time ate away the electric tape and one of the wires was hitting the cover so it was grounding the whole thing out.

I electric taped the crap out of everything and its fine now. I'm going to end up ordering another stator but I know my taping will hold up.

You might want to open up your stator and take a look. If you haven't yet


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