Okay so I will give a run down of what the bike has done and what it is doing now. Bike is a 2004 Honda CBR600F4i, bought it and the battery seemed to be dying, so I replaced it. Bike ran fine for a day or two but then wouldn't start, again sounded like the battery was really weak, but it was brand new.

Did some research and thought it was the R/R, so I replaced that. Put the brand new one on, bike did the SAME thing. Had advance charge my battery for 24 hours, thinking maybe the battery was fried on the 2-3 trips with a bad R/R, but they tested it good and charged it full. Bike sounded like the battery was dead. Now, if I put it on the charger and jump it, it fires up fine. I can ride 5 miles with no issues as long as the bike is on, nothing feels off. Could probably go further but I don't want to harm the bike.

Voltage to the battery when the bike is on is right around 12-13v at idle on a cold start, haven't revved it up to 3-4k RPMs and checked voltage there but I plan to soon.

My only other thoughts could be: Bad stator, short somewhere, bad ground somewhere.

So in short; The bike will not start on a fresh battery, but will jump and run fine when it is on, has pretty normal voltage when on, dies after even being turned on once.

Any ideas guys?

 

Your charging system is still acting up.
Test it as detailed in the service manual. But in a nutshell...

Stator terminals must have continuity to each other and no continuity to ground
The system wont charge at idle. Take a reading on the battery at 5k rpm, looking for 13.5v to 14.5v.

If your stator tests bad, the new r/r may have been damaged. Hopefully not.

 

Use this to test your whole charging system:

http://www.electrosport.com/media/pd...ng-diagram.pdf

I recommend following the wires all the way from your stator to the RR and then to the battery. I ended up finding a connector that had melted on the yellow wires (stator) that was tucked behind the left side frame/fairing

 

I am way below voltage now, even with the bike warmed up. Went for a short, short ride today after bike was at normal operating temps and realized that when I ride at a constant speed/RPM the bike feels all though its breaking up. I am thinking the coils aren't getting enough power, making it a bad stator. Just ordered a Ricks motorsports off ebay before work, hoping that does it! If not I may drop the bike off with a buddy who is a full time bike mechanic to help me figure this out. I figured since I got a new R/R and just ordered another new battery, might as well do the stator too. Riding season is coming up, gonna be worth it!

Again, I am very new with bikes, coming from boosted cars, but I have a very good understanding after extensive research. But if any of what I am saying doesn't make sense, I am sorry and feel free to correct me.

 

Thank you!!!

Funny thing, my Dad was doing some research when he was at work today on my bike and when I came home tonight, he had a full print out of that EXACT diagram he said he got off someones post on CBRForums. Kinda funny!

 

Just wanted to update so if anyone searches and finds this thread and they have the same problem, [B]it was the stator.[B] Bike runs 110% now!