Here, this might help:

 

I just got my first KQ750 and had the same issue. I did all the tests on the regulator/rectifier and the stator and they both fell within specs. I checked the starter relay and there wasn't any continuity from the battery side to any of the "small" pegs in the plug. I got a new one and there is! So yes a bad relay can stop the power from returning to and charging the battery. I haven't been able to check for sure yet as I'm still waiting for my new starter to arrive. But I'm quite optimistic that my charging issue may be resolved.

 

When I checked my starter relay only the top 2 small pins have continuity. Should the bottom two small ones have continuity as well?

 

A follow up on the charging on a 2013 750 KQ. I was correct in the assumption that the power does indeed go through the starter relay. My starter went bad and in the course of using it it overloaded my relay. The relay still worked to turn the starter but it would not allow the power to go back to the battery. I installed a new starter as well as a new relay and all works. It still doesn't charge the way I'd like to see but at a fast idle it puts out 13.8 volts. I'm thinking the regulator may be a bit on the bad side from all the other issues. BUT it does charge now.

 

Mine will charge at 13.3 on idle but drops to 12.6 when a bit of throttle is applied. I think the quad has been like this for a while and I blamed it on the battery (7years old). I noticed my dash light for years has always flickered when the lights were turned on. I have a napa glass mat battery, same as the old one, one year old and now likes to sit at the same voltage the bike will put out when throttle is applied ( 12.5 to 12.6). Charge it and it will hold 13.8 volts for a 1/2 hr and gradually drop back to 12.6. I am thinking the regulator is not putting out the right amount of power. All other connections seem great and test as should. Stator puts out more than 75 volts AC when at 5000 rpm as stated in the shop manual. My multimeter doesn't read the diodes in the regulator like is shown in the shop manual, but the same as in youtube videos so I don't know what to say there. I get on avg 630 to 670 doing it the youtube video way but its not whats stated in the shop manual. I get great continuity on the red wire from the regulator to the starter relay and to the battery and also the black wire checks the same. I am thinking its the regulator just not putting out the power it needs to when driving. It is worse if I use it night time, it will stall time to time when the fan cuts in and your slowing down ( I guess the break light on aswell). I have a neighbor who has the 700 kingquad. I am guessing they have the same charging system his is the year before mine. Curious to see what his charges at. When I figure it out I will post what the issue was.

Thanks for the replys

 

This is exactly what mine was doing.13 something at idle and 12.6 or so when running 3000+ rpm. I replaced the Rectifier/regulator and it's right where it should be.( I did run a separate ground wire from the reg/rec to the neg of the battery) 14 plus volts and holds 13.8 plus with lights on.I will admit that I did get a "Blue Elf" regulator instead of Suzuki but I've logged a little over a hundred miles since and it still works perfectly.

 

Thats awesome. Glad to hear it worked. I think I just might go ahead and get a regulator and give it a go. I will post the results.

Thanks for the replys.

 

I am extremely curious to find out what cured NewfieSuzuki's problem, if it was the regulator. I am having hte same issue (charging 13.5v at idle, 12.8v with light throttle, 2000-3000rpm).

 

My issue was the yellow wires from the stator. There must of been a bad crimp in one of the wires in the plug ( 3 yellow wires plug into the harness). I cleaned the same plug last year when I put the rectifier on and even checked the same plug for corrosion. Tested and found to be getting the right voltage. This passed september I went for a weekend trip and I could swear I could smell plastic at times. The quad stalled at random all weekend. So I went to check the plug for corrosion again and it was melted together inside. The plug looked normal on the outside. Couldn't get it apart without using pliers on both side of the plug. I crimped and soldered some new ends on the wires and connected them the same way they were originally. Double shrink wrapped the 3 wires and been best kind ever since. Voltage doesn't drop when I turn the lights on, rev it, or even with the light bar on. That issue been doggin me for years off and on.