***Second attempt, first never published***
Hi folks, I'm new to the forum and hoping for a hail Mary pass from someone here to help with a real headscratcher of an electrical challenge.

I picked up a 2015 KLX250S as a non runner (standard bike, EU/UK model), turns out the CPU was fried, changed with new Kawa OEM CPU and bike is running fine BUT it overcharges.

So far we've tested/replaced:

Voltage Regulator - tested with three different new Volt Regs, bike sits with a new Kawa OEM unit at present but still no dice, still over charges
Bike had incorrect Stator/Generator fitted, we pulled that and replaced with new Kawa OEM unit, better, stable but still overcharging now at 17.5 volts (with incorrect Stator volts would just keep climbing to 19+ before we cut the engine to save the CPU).
New battery, tested and all good and tight at 12.8 to 12.9 volts
New earth strap/connections
Checked wiring loom, OEM and no signs of hacked wires

All electrical components and systems (lights etc) function correctly.

Has anyone come across this sort of over charging challenge before? Bike is a clean straight machine in good overall condition, full factory new charging system yet still the over charging challenge.

Thanks for reading

 

There are 3 wires going into the VR. One from + on battery, one to - on battery, and one going to ignitor (BK/Y). IMO, one of those wires is not continous, check with the VR & ignitor disconnected, I suspect the +.

 

Thanks for your reply, I got a feeling we already tested those a while back, but worth checking again.