Charging system. Stator and/or most likely the reg/rec.

Download the factory service manual and follow the troubleshooting procedure for the charging system.

 

Charging system. Stator or most likely the reg/rec.

It would be nice if it were only the reg/rec but my money is on the stator. Unfortunately.

 

How did they test the battery?
Do you have an electrical tester?

 

Yea, they used some battery tester... everything checked out, I just ordered an electrical tester on amazon so I?ll have it in 2 days... gonna try and diagnose the stator and reg before replacing parts that don?t need to be replaced (fingers crossed it?s the reg)

 

I still wouldn't be surprised if it's the battery. Seeing as it wouldn't start the bike, I don't see how they could test, you can't properly test a flat battery. Also the fact that you rode for 2 hours and the bike didn't quit leads me to believe it's trying to charge the battery, it had enough to keep it running but not enough to start. Once you get the tester though you'll be able to test easily enough.

 

Been there, learnt to park facing downhill. Yes, the charging system puts out just enough to keep the bike running, but the battery gradually loses charge. So you charge the battery, it starts the bike OK, you ride for a couple of hours, then it won't start.

 

I can say I've had first hand experience on both accounts of a stator failing and a regulator failing both on separate long distance rides. The first scenario the stator failed on 1 field and on long distance rides 1 hour plus it was fine but any short runs say 30 mins or less it wouldn't start. Just enough voltage for it to do this but it has happened... Second scenario I was on my way home with 150 miles to go and my headlights started acting up from the regulator over charging so I took it easy and at 3am about 20 miles from home my lights dropped out and didn't come back on until I stoped and I made the fatal mistake of shutting off the bike there I sat 20 miles from home 3am in the country lol! Once the regulator completely died I probly only went 50 miles..
So I've seen first hand both situations and you can go along ways (sometimes)
But 90% of the time the stator fail's not the regulator. And anytime a regulator fails they usually over charge or flat don't put anything out!
So take my advice check out the stator at least test it.
Also if you had a parts house test your battery if they have the new electronic testers they don't lie, they give a reading for everything! Even if it's dead will tell them to charge and retest the battery...

Oh by the way here is a link to test the entire charging system. ALSO check stator phases to a good ground! And verify it's a good ground!
http://www.electrosport.com/media/pdf/fault-finding-diagram.pdf

Also if your stators bad buy a ricksmotorsport stator! If your regulator is actually bad buy a genuine fh020aa but make sure it's not a fake. It has to say fh020aa on the end of it!

 

i just fixed an issue exactly like this on an 06. battery was good charging system was good. seemed like low battery but when you put a volt meter on it it said 12.8, when you try to start the bike it would dip low to about 8 like the battery was bad but with an actual battery tester it tested fine. jumped it from another battery and it started up but it turned out to be the bushing in the starter was starting to seize up and was drawing a lot of power just to move it.

put the battery on the charger to make sure its full, should be above 12, put the volt meter on the battery when you go to start it and see what it drops to should be above 10 when cranking. if it goes below theres an issue. if it cranks a bit then stops and dies its the battery. if it cranks continuously slow then it will be something else. if it cranks continuously slow, crank for 10-15 seconds and see if the terminals get warm thats the starter overworking or a bad connection.

if you get it started you want to see 12.5-13.5 at idle and 13.5-14.5 when u rev it to about 3K rpm and hold it there a couple seconds. you don't want to see it go higher then 14.5. each bike varies thats why the numbers i gave you vary so much but thats pretty general so outside of those numbers theres an issue and in the manual theres more thorough testing methods.