Update....my problem, or a new problem, is back!
Everything was running fine up from my last post date. This was after the fried stator was replaced with a new one from RMStator. Fast forward to December'ish. Battery starts acting flaky, like it won't hold a charge. This progresses into the battery dropping significantly (below 9v) while cranking. Pulled the battery, took it to the local battery place, and wouldn't you know that it was out of warranty by a couple of weeks. They did help me out with a reduced price new one, though.
New battery in, and all is right with the world. Fast forward to the following week, and I have to jump start it to get home! This is on a bike that's ridden daily, albeit that my commute is relatively short with little freeway time, but still. Off come the side panels, and I can't seem to get more than 12.7-12.8vdc at the battery, either at idle or RPM. I immediately regret my decision of only replacing the stator, and not the R/R at the same time. RMStator.com, new mosfet R/R, add to cart, a few days later and it's installed. Good to go? Not so much.
I'm still struggling to hit 13vdc at the battery, at RPM. If I hold it long enough, it creeps up, but way too slow, and nothing north of 13vdc. Broke out the multimeter, and checked the stator thinking maybe my original R/R fried the new stator, but it's putting out ~26vac on all three legs at idle, and 60-80vac when revved. Pulled the R/R connector, and reading 15.5vdc at the regulator...so it's making voltage.
Next step...unhook all accessories, and see if there's a power draw somewhere. Disconnected aux lights (3x 28W pods). Recheck battery voltage while running, same. Disconnect GPS plug, same. Disconnect Skene dimmer, same. Disconnect left LED headlight (30W) bulb, voltage improves slightly! Disconnect right LED headlight bulb, and I can consistently get 13vdc at RPM. There should be enough power output to run everything mentioned, and still get 13-14vdc at RPM...
I've ran the above electrical accessory setup for years with no problems (other than the occasional left headlight bulb burning out, but "they all do that?!"). It's recently had the throttle body recall done, but I don't think the problem is related. It's also had the headlight harness recall done, but that was years ago. Now I'm sitting here, scratching my head, and wondering what I'm missing??
Edit: I just remembered that I added LED signal bulbs (fore/aft), and a new LED flasher relay. Surely that's not it, but it's getting checked now!
Edit: Flasher relay out of the system, no change. Tried a different multimeter for fun. I'm still not getting the 14vdc I'd expect, but it does creep up slowly...about 0.01v every couple of seconds at RPM. It will eventually make it around 13.3vdc, but the headers are hating life. Wayyy too slow in my mind.
Thanks!
-Luke