So I'm completely at a loss. I had an issue last weekend while on a run, I stopped for gas and afterword the bike wouldn't start just clicked. I jump started it off another bike and was able to make it the next 40 miles without an issue. But as soon as I shut it off again, I experienced the same issue, starter just clicking and a dead battery.
I pulled the battery and had it tested, came up with a dead cell, so I bought a new one. Installed it and rode all weekend including a 200 mile trek home without an issue.
It sat for about a week and I went to start it today and again nothing, the headlight would barely light up. I had the battery charged at work, hooked it back up and it started fine but the battery is only reading 12.2 volts while running? I ran through the check list of charging system checks and as far as I can tell everything appears fine.
I'm getting roughly 42 volts out of the stator, I also did a stator IB test and received no continuity to ground, which should be correct.
I did a diode test forward and reverse on the regulator and that tested good as well I think. I believe I should be seeing about .5 volts my multimeter set on the diode setting. I was reading 485 on one lead and 500 on the second. Not sure if this is correct and my meter is set to the wrong scale?
Other than that I'm at a loss and really can't figure out why this thing isn't charging? Any help or suggestions would be amazing!!!

 

How old is the battery?

 

Nevermind, re read your post and see it's new.

 

ground wire clean and tight ? + clean an tight , ground to frame also ?

check the wires close for corrosion at the battery and the ground to moto

you should see the battery voltage increase with rpm - very odd
all the test seem fine hmm

 

I checked all the wires and everything was tight, I cleaned the battery terminals when I changed the battery. Even checked to make sure the regulator was tight too. I checked the ground to the frame and it was tight, I'll pull it off tomorrow and make sure that's clean as well. But I wouldn't think it was bad since it was tight and never taken off, but I could be wrong.

 

if u want to check your results i think this should help ya

http://blog.jpcycles.com/step-by-ste...arging-system/

 

There's also a positive connection on the starter. The battery doesn't charge at idle, only above 1200 RPM. Could also be the start relay.

 

You should be reading approx 14 volts at the battery when the bike is running. If no voltage increase with increased RPMs, and the stator checks out okay, I would think you've a bad regulator.

 

check the connection at the regulator plug - do the pins look corroded or lose or screwed up , or melted? make sure the plug really does make a GOOD connection

my buddy had a problem like u describe - i just remembered it now lol
same thing happen -- turns out his plug was corroded and almost melted, which i guess was from a lose connection , and wasnt making good connection - we fixed plug ends and all worked great after this -- just a thought

 

It starts fine without issue once the battery is charged or jumped, so I wouldn't think it had anything to do with the starter or relay. I checked the battery voltage while running with full choke and hitting the throttle and still the voltage doesn't go above 12.2?