I've been absent for quite a while due to being busy with work and study, but I thought I'd share a recent experience in case it helps someone out.
Yesterday I finished work early, around lunchtime, and was riding home, it was about 32ish celcius or 90F, so it was hot, but not as bad as it'll get when it hits summer soon.
I made my way through a busy intersection and started to accelerate up a hill and everything shut down, the tacho stayed on 4500rpm and everything stopped responding. I pulled over to avoid getting cleaned up by a semi/ B-double/ Lorry depending on where you're from.
Did the usual checks, fuses and so on, nothing seemed to get it started. I couldnt get to the main 30A fuse while on the side of the road so I pushed it to the shopping centre further down the road. Still couldn't get to the fuse without lifting the tank off.
Managed to push the bike home where i could pull it apart. The 30A was blown, but I wasn't happy with just replacing the fuse, I needed to know why it blew. Jumped on the forum, did some searches, found a lot of information on dodgy R/R units so figured i should run some checks on the charging system.
Checked the batter while running and it was only putting out 12.7V and kept dropping slowly. So I put the battery on charge overnight (still connected to bike).
I then checked the battery in the morning and it was showing 5V. Obviously, the bike wouldn't start and couldn't be jump started. Connected up a new battery and the bike started, but the voltage sat around 12-13V before steadily dropping while the bike was running.
Now that I was sure the charging system wasn't working, I pulled out the R/R and it was burnt out:
I figure the exposed wire shorting was the cause of the blown fuse.
I called my local dealer to price a replacement and they quoted $540 for a new one. I'm not paying that much for an R/R so I did some research and came across http://ricksmotorsportelectrics.com/
I placed an order with them for a MOSFET R/R and got it express shipped for under $200, thank you America
It's ruined a perfectly good Saturday out riding, the first sunny saturday in a few weeks, but that always better than it happening on my weekend trip in two weeks
Bit of a long post, but figured someone might benefit from reading it if they're going through the same issues and haven't stumbled upon the multitude of other info on it.