OK so went for my first run out on the TLR since purchase last week and various elements of work (replacement ECM/Fuel Pump Relay/Starter Relay). Have done a shed load of other jobs too - new grips, levers, taken all the nasty aftermarket decals off, put the proper colour matched front mudguard, original silencers on and so on!
Anyway, ran well - it did do the 'die and flashing FI LED/FI in LCD' trick twice and BOTH times it was when drawing to a stop and I let the revs die - as we know it is only ticking over at 800 rpm until I sort the frozen throttle adjust/set the TPS/balance the bodies. I very much get the sense the cutting out is being triggered by the system because its too low rather than a fault with the system per se - that's what I'm hoping anyway. When under load, when cruising, when ridden hard, there are no issues - except the very occasional cough when accelerating out of a corner - but that's probably balance/TPS and crappy injection mapping.
So, I managed to do 76 miles to a bike meet, and on the way home, a further 14 miles, the LED came on and the engine died. When we left the bike meet, I simply got the dreaded click and we bumped the bike. 14 miles later it died. The Red LED came on and the fuel low light flickered. Battery appeared totally flat.
The battery was absolutely red hot on inspection and touch, and also, we we parked up (twice) both my son and I commented on the 'what is that sulferous smell!!??'.
I rode my sons bike home, picked up the van and got the bike home. The battery indicated 13.1v but it would not crank the bike. I fitted a spare charged at 12.8v and the bike started straight away. Rode for 2 miles and came home - tested voltage across the terminals with the engine running - 12.8v.
Unplugged the alternator (the 3 yellow wires) with the engine running and got 56+ volts AC. Test the red/black coming out of the regulator - absolutely zip. Suspect regulator dead - but why was the battery absolutely frying and super hot??
I have a confession to make - the battery I was using had been sitting for 12 months. I thought it was OK - a Yuasa.
So, BEFORE i buy my way out of what I think the problem is (Regulator/Battery), your advice will be very welcome.
Sorry for the length of this .......... I'll be able to write a memoire at this rate!