Thanks tomacGTi for the PM. I just wound up using the Dealer Honda/Suzuki in San Mateo closest here. I figured my cheap HarborFrieght free-multimeter measurements were way off and I was hoping that dearler would get OEM parts the faster than Cyclegear or BikeBandit.com. If I wasn't in a hurry to get home tomorrow, and had more tools I could have done it all myself easy and cheap.
It was expensive and inconvenient, but a good lesson learned in the end. Voltage doesn't get immediately sent from the regulator all the time; at least on my 400. The high beams, radiator fan and revs over 6K all have to happen before it will start showing 13-14 volts on the battery. The rest of the time the battery just holds at 12.5V. I was giving up on my measurements too early and freaking out thinking I lost my stator when really I just needed to calm down and learn more about the quirks of my charging system. Hopefully I'm truly all good this time and can make it home without any more headaches or money spent. The 500 miles up here only took 1/4 of a quart of oil. As long as I fuel regularly, stay out of traffic or hot areas I should have a fun ride this time around.
If you all haven't tried it this fuel planner is pretty amazing!
fuelmyroute.comYou can plan your gas stops by price or convenience!
Be careful on the twisties roads vs the hoghways though. On my bike I coast and draft on the freeways an get close to 45MPG, but in bad traffic or twisties uphill which isn't always clear I can drop as low as 29MPG. Best to be extremely conservative on your route stops.