I did not post a follow up, but I replaced the R/R, part number 31600-MV4-010 on Oct. 12, 2004. (see my first post on 10/10/04 on page 8. That
was the problem, no doubt about it. I also put 2 CPU cooling fans around it to keep it from getting too hot. I have decided to leave the volt meter up on the guage cluster. It is small enough not to be a nuicance, and I like to be able to see where the volts are.
These posts that are saying that the battery will not charge below 5-6k rpm are totally false.
Sitting at idle and or riding at 2-3k rpm WILL NOT DRAIN THE BATTERY! I don't care what any manual or mechanic says, the volt meter doesn't lie.
After replacing the rectifier, at an idle of about 1100 rpm, my volts are between 13.6 and 14.1 VDC. At 6k rpm and about 100 mph, I am between 13.8 and 14.2. During a hot Miami day cruising South Beach, I can be at idle with the fan on and still be at about 13.2 + VDC. I have never seen it above 14.4. If your battery is fairly good, and your bike is not restarting, you better check the R/R. The easiest way is to rig a voltmeter, the one I got is from Autozone, you can see a picture of it here:
http://www.cetsolar.com/voltmeter.htm I used a cigarette lighter extension plug, and ran wires from my battery, under the tank, up under the guage cluster with the plug end just behind the tach. Then I put a piece of velcro in between the tach and speedo and mounted it right there.
With the bike off and battery charged, you should get between 12.3 to 13.3 VDC. Start it up and ride around for at least 30 minutes. If your volts ever drop below 12.6, your R/R is bad. It may take some time to see it drop, or it may happen right away. With mine, it would start after about 10 minutes of riding, regardless if it was on the expressway at 80+ mph, or in stop and go traffic.
You can get them at the dealer for about $125 to $150, or if you can wait a week or so, you can get it here for $70 + s/h.
http://www.mugen571.com/RVF400RegRecUpdate.htmlI hope this resolves any questions about this common problem with the R/R.