For the last few weeks, I've been having charging system issues on my K7. It all started with my HID light going out on me at 11 pm, over an hour from home. I traced that issue back to the ballast, and replaced the failed unit (warranty). I ride the bike locally a few other times during the week before departing on a rip out Lougheed on Saturday and then up the Canyon to Boston Bar. The bike experienced no issues and ran fine...or so I thought. Once I got back home, I shut the bike off, I heard a loud whistle and what smelled like rotten eggs. I traced the sound to the battery area, pulled the seat off, and sure enough, it was the battery. It was swelled out slightly and smoking, so I quickly removed it from the bike. Using a multimeter, I checked the voltage off the R/R, at 5,000 rpm it was spiking over 17v...thus over-charging the battery. I replaced the battery with a fresh Yuasa. I then replaced the OEM R/R with an ElectroSport, which has now failed after only two rides. I've got some more tests to do tonight, as I want to see if my stator is generating enough AC current (should be about 65v per the manual). Currently, I'm not getting anything more than 12.5 at the battery (with elevated rpms).
I know charging system problems hav plagued the 2006-2009 gixxers, but only the 08 and 09 units were involved in the recall. Has anyone else had these issues and could recommend a plan of attack? I know it basically comes down to sourcing the issue in 1 of 3 components (the stator/generator, the R/R, or the battery). I sold my house and am now in a condo for the time being. Needless to say, working on the car / bike in a parkade is a PITA. If anyone in the Tri-Cities area could lend a hand or some expertise in this area, it'd be greatly appreciated. And yes, there's beer. I can do most any repairs myself, but wiring and electrical has never been my fortay. Thanks guys!