well, my agony continues.
Anyway, the shop recommended that I replace the voltage regulator initially, that didn't work. They credited me for the regulator and determined that the amp output was not up to spec, so replaced the stator. Went for a 47 mile ride around town, and things looked good, so I took it out for a real ride and sputtered to a stop 50 miles from town. Luckily I was only about 200 yards from someones campsite, ironically was the second person I had seen in the 50 miles. They gave me a ride to a place with phone reception.
Sometimes replacing a bad part with a "new" part, then confuses the diagnosis. I'm not a big fan of those Lithium batteries. Make sure it's a good one, also that bike should kick start with little or no battery. Either that battery sucks or something is a major drain dropping voltage to the point the ignition won't fire it. I don't think riding it will do that. Check voltage draw with the battery charged and the bike off.
This is the third battery, the original, I replaced it, then again with the Li battery. The Li battery is not as good as the others in my opinion. When it gets low, the motorcycle sputters to a stop. the other batteries would at least carry me until I turn the bike off, or stalled it. You indicate that it should start regardless using the kick starter, I would agree, but my experience says no. The bike will hold charge with the button turned off. Just not when its driving down the rode. With the button on, and bike off, I am sure it will go dead, as I have done that before when it was operating correctly. May be sooner, but have no way to gauge that.
Took it back to the shop yesterday. The shop was going to recheck the work they had done to make sure things are functioning. I told them I thought it was a draining issue not a charging issue, started the bike to show them how bright the headlight was, and the head light was not working, weird because I rode the bike in the dark on the 47 miler a couple rides ago. Seems like this problem is destroying components left and right. Anyway, I told them to hook a meter to it and go for a ride.
I am considering a new motorcycle now. Finding that new Yam's don't have the 6.6 gal tank anymore, seems only ktm has large tanks available anymore, a 5.4, may have to go that route as I frequently ride 200 miles in a trip. Even if I purchase a new bike, I will need to fix this thing to get rid of it. I really like the wr, I rode the ktm sc-w 500 the other day, and I think the wr has better bottom grunt then the ktm. Further, I have installed a heavier rebound and springs in the front end of the wr to carry the extra fuel and my much greater than 180# self. The tires, sprocket, and chains are new. Carb is tuned. All the general wear items I have replaced for this season. I hate to purchase a new bike for $9100 and have to dump $1000 in parts in it to get to where I am now. (new tank, heavier springs, sprocket,chain, mirrors, horn, taillight) KTM store doesn't have an exc 500 on the floor, which would be better as I would not have to add the street legalization gear.
Anyway, I think I was dumb not asking for a demo bike to ride in the mean time. I do know that it is this shops last try at the problem.