I was going to start a new thread on this, but this seemed relevent. I was having charging problems with my bike, I am on my third battery in 18 months since I bought my bike new. When you put a voltmeter on the bike while it was running it was showing 13.5 volts but my battery was continually going dead unless I kept it on a charger all the time. Took it to the dealer and when they tested it they found that it would test OK when they first started it up but then the voltage would drop when it got hot. A new voltage regulator was ordered under warranty and after it was installed it was charging at 14.3 volts. I think that the rewiring with a heavier guage wire sounds interesting and certainly sounds reasonable, perhaps the factorys light guage wiring helped lead to the early failure of the regulator? The only accessory that runs off the electrical system is the factory lightbar, I wouldn't think that would overtax the charging system.
