Okay, so last week was my headache trying to get the headlight to come on when it was just the bulb burned out! I'm hoping this issue is as simple to fix! 
I rarely if ever have any problems with this machine, but when I get the occasional minor issue I tend to go overkill and replace parts rather than fix existing ones 
To bring you up to speed, within the last few weeks I have replaced:
Wiring harness (OEM), 1980 Special II
Clutch side control (lights, horn, etc) switch (OEM)
Headlight (direct replacement, sealed beam halogen)
A few weeks before that I ran Seafoam through the carbs and replaced the rear tire, rear sprocket, and rear drive chain. (Mentioned simply for reference)
Up until yesterday I was very happy....engine running smoothly (great gas mileage, fast acceleration), head/tail/brake lights BRIGHT, blinkers bright and steady, and horn blowing. I thought I had it made!
Then, yesterday I was on the highway and something very unusual happened that I had not experienced before. My bike started to jerk two-step whenever I changed lanes, and for the first leg of my trip I thought it was from the gasoline sloshing in the tank and away from the petcock (tank was neither full nor very low at the time). Something else that I noticed was the red brake-light indicator was lit (sometimes fading on and off, but fully lit at times).
Things got worse on the way home (this trek was about 60 miles roundtrip). I discovered that every time I turned on my blinker, the engine would jerk. Pretty soon the blinker indicator became so dim that I could not even see it. Again, that little red light stayed on. Shortly thereafter my bike just died, zero power! I pulled to the shoulder on the highway and had to call AAA to take me home. The ignition wouldn't even buzz when I tried to restart it, and even the green neutral light wouldn't show. Basically, dead.
I knew I didn't run out of gas, so my next and most logical guess was something electrical (again!). When I got home the battery read about 10 volts. I charged it and left it unplugged from the harness overnight to see if it would hold a charge. When I checked it this morning it read 13 volts. So indeed it held the charge.
I reconnected everything and started the bike. About 12.37 volts at idle after a few mins. Revving to 3000 RPM registered only 12.40 volts, leading me to believe it is not charging. (After I installed the new harness a few weeks ago I tested voltage and it jumped, indicating charging. So this is recent problem.)
After 10-15 minute stop/go ride the voltage read 12.28 volts. But 3 hours after I shut off the bike, voltage was back to 12.72 volts.
A couple things:
The battery is only a few months old so I doubt it's the problem.
I replaced the alternator brushes at the same time as the battery.
Fuses were not blown and box is brand new (along with rest of wiring harness).
Wiring harness, again, brand new and all connections tight.
Alternator passed the "slap" test and the magnetic effect was not weak.
Headlight seems to get slightly brighter/dimmer when revving, hard to tell with new bulb.
Both brake light and tail light work fine, which makes me suspicious about the red indicator lighting up for no reason. Grounding issue???
I have original TCI ignition and alternator and stator. RLU and safety relay (headlight portion) were bypassed previously but never caused a problem (again, just for reference). Don't think ignition coil is the problem as it runs fine when charged, maybe I'm wrong. I did not test the regulator because I assumed that passing slap test meant it's fine. I really have no idea what else it could be. Ideas??
I have been very specific here because I don't want to throw off anybody and get canned answers. Thanks.
I rarely if ever have any problems with this machine, but when I get the occasional minor issue I tend to go overkill and replace parts rather than fix existing ones To bring you up to speed, within the last few weeks I have replaced:
Wiring harness (OEM), 1980 Special II
Clutch side control (lights, horn, etc) switch (OEM)
Headlight (direct replacement, sealed beam halogen)
A few weeks before that I ran Seafoam through the carbs and replaced the rear tire, rear sprocket, and rear drive chain. (Mentioned simply for reference)
Up until yesterday I was very happy....engine running smoothly (great gas mileage, fast acceleration), head/tail/brake lights BRIGHT, blinkers bright and steady, and horn blowing. I thought I had it made!
Then, yesterday I was on the highway and something very unusual happened that I had not experienced before. My bike started to jerk two-step whenever I changed lanes, and for the first leg of my trip I thought it was from the gasoline sloshing in the tank and away from the petcock (tank was neither full nor very low at the time). Something else that I noticed was the red brake-light indicator was lit (sometimes fading on and off, but fully lit at times).
Things got worse on the way home (this trek was about 60 miles roundtrip). I discovered that every time I turned on my blinker, the engine would jerk. Pretty soon the blinker indicator became so dim that I could not even see it. Again, that little red light stayed on. Shortly thereafter my bike just died, zero power! I pulled to the shoulder on the highway and had to call AAA to take me home. The ignition wouldn't even buzz when I tried to restart it, and even the green neutral light wouldn't show. Basically, dead.
I knew I didn't run out of gas, so my next and most logical guess was something electrical (again!). When I got home the battery read about 10 volts. I charged it and left it unplugged from the harness overnight to see if it would hold a charge. When I checked it this morning it read 13 volts. So indeed it held the charge.
I reconnected everything and started the bike. About 12.37 volts at idle after a few mins. Revving to 3000 RPM registered only 12.40 volts, leading me to believe it is not charging. (After I installed the new harness a few weeks ago I tested voltage and it jumped, indicating charging. So this is recent problem.)
After 10-15 minute stop/go ride the voltage read 12.28 volts. But 3 hours after I shut off the bike, voltage was back to 12.72 volts.
A couple things:
The battery is only a few months old so I doubt it's the problem.
I replaced the alternator brushes at the same time as the battery.
Fuses were not blown and box is brand new (along with rest of wiring harness).
Wiring harness, again, brand new and all connections tight.
Alternator passed the "slap" test and the magnetic effect was not weak.
Headlight seems to get slightly brighter/dimmer when revving, hard to tell with new bulb.
Both brake light and tail light work fine, which makes me suspicious about the red indicator lighting up for no reason. Grounding issue???
I have original TCI ignition and alternator and stator. RLU and safety relay (headlight portion) were bypassed previously but never caused a problem (again, just for reference). Don't think ignition coil is the problem as it runs fine when charged, maybe I'm wrong. I did not test the regulator because I assumed that passing slap test meant it's fine. I really have no idea what else it could be. Ideas??
I have been very specific here because I don't want to throw off anybody and get canned answers. Thanks.
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I tried the jumping suggested in the charge guide but it didn't do anything 
So is it the culprit or not is what I'm wondering 