Any other way to test this without swapping out the regulator?

 

I did every test on that list, only ones I couldn't get accurate measurements on were the resistance tests, since my cheapo meter doesn't have an ohm x1 scale on it.

 

Nothing corroded nothing melted, but when I pulled the stator plug apart the terminals had oil on them. Apparently residue left over from changing out the oil filter. I cleaned the terminals good both sides and put everything back. Didn't think that would be an issue anymore but who knows.

 

There are two Stickies in the Tech Electrical section that will help you check and diagnose your charging circuit. Don't replace anything until you have identified the problem! Buy yourself a multimeter for around 10-20 bucks.

 

Agreed. Purchase a better digital multi meter and read the troubleshooting steps. Appears that your system is not charging.

 

It's definitely not charging, well at least not like it should be. I ran through the tests in one of the stickies and I get no continuity from the stator leads to ground as it should be I also checked the leads going into the regulator with a test light and there was no light again as it should be. The only test i'm having trouble proving is the resistance test with the stator. I might need to get a better meter mine only goes as low as a 200 ohm scale, set to that I am reading .9 across the leads going to the stator? I pulled the inspection cover off the primary too, just to make sure I didn't get a nasty smell, as others had suggested. Although I really don't like the smell of 90 weight oil, it smells no different in the primary than it does in the bottle new.

Just wish there was something that would point me in a definite direction.

 

very weird . have to keep us updated on this one - i will have to dig into my book an have a look

 

You come up with anything I haven't tried yet, lemme know.

 

you checked the stator and it tests good when running and it is not shorted, so all is good there...the regulator tests good BUT you are not getting the proper voltage at the battery...So I would check the voltage at the output to regulator to see if you are loosing it on the way to the battery..if the voltage is low at the regulator even when you rev. it up some it is the regulator....if it is good at the regulator you have a issue with the wiring between the regulator and the battery....have you had the new battery load tested just to make sure its not faulty?? stranger things have happened....another thing that bothers me is that it went dead when the bike was off for a week, I would check to make sure that you don't have another issue with a short somewhere (bad regulator diodes can cause this issue also)....I don't have a wiring diagram near me, but it seems to me that the charging wire between the reg. and the battery goes some other places (fuse box?? ignition??) anyway check all that out, it only takes one funky connection to stop the battery from charging ...

 

I believe there is another start relay that energizes when you turn the key on ..different than the one for the starter motor relay, and if it is stuck it will cause your battery to go dead when the key is off....like I said I don't have the wiring diagram near me (I am at work and it is home) so I am kinda just pulling stuff out of my orifices)....