Firstly big thanks for Onewizard for the patient replies, his inbox must be flooded with questions from the likes like me I imagine.
To share through my own experience of the Polaris series R/R install.
Firstly I bought my 2009 Versys second hand 2 months ago, and noticed that the mileage was around 63+k rpms, and I read up about the stators burning up around that mileage, so I thought better to get it checked.
I had never touched a multimeter in my lifetime, but this is really doable - maybe except for the crimping, I had an electrician colleague
Performed the stator test before installing a new one as guided by Onewizard. Set RPMS to 2000K with idle screw, had 100rpm fluctuations because the bike needed a vaccum sync, but I ensured I took the highest readings during the RPM fluctuations. VAC generally read A, B, C read 19.5, 22, 24 - disheartened, it was really on the way out. Confirmed when the stator was pulled - Old stator was really burnt, badly in fact, two 5mm black burns on two winds, edge of stator, whew! performing the test definitely saved me a the unpleasant stranded situation by the road.
Thankfully early detection also saved me the battery, as it was still healthy at tests, so I knew I wanted the replacement done fast to preserve it, as it was new and a pricey german one:
14V @ 3kRPM
1.275V @ static
Old stator was still charging, but twas a matter of time.
Bought a Polaris online, and requested specifically for the serial number to be shown, which verified the correct type, around 60 USD paid for it with shipping, was a gamble I was willing to take with the current prices of the R/R new.
As per Onewizards advice for electical skills challenged people, I also bought a Triumph harness, with shipping to Singapore was pricier than the full DIY option at around 22USD, but was a price I was willing to pay as I also wanted a robust waterproofing solution with the torrential rainfall we get here.
Had to ride across the border from Singapore to Malaysia as Kawasaki support in my country is horrible, got the stator changed, went directly went back to Singapore to the office to recruit my electrician colleague and began surgery work on the V.
First time taking off the fuel tank, took awhile to take apart the bike.
1) Disconnected the battery
2)Reached below the tank to tap the black to the grey wire at the center fuse box plug to remove the parasitic drain, spliced them and taped them up with electrical tape, capped the black wire.
3) Replaced the R/R, Snipped off the original, this took patience as the access to the screw to remove the R/R was limited, so small turns on my small wrench, but eventually got it off.
4)Triumph harness worked a treat. crimped the connectors to the original wiring with some butt splices bought from an electronics store, then heat shrunk them for waterproofing, black taped them individually, then another application of black tape around the 5 wires. capped off the unused earth wire. installed the new R/R. I plan to get some wire loom to reduce friction wear on the tape.
5)Prayed, then fired her up. Success! the Polaris wasn't a dud!
a)R/R test went well, all readings are in the 16VAC region, taken from behind stator side plug, sticking multimeter pins into the rear of of the connecter
b)New stator read at 24, 24.5,25, looking good!
c)With the Polaris, the battery is reading 14v @ 2k rpm and 14.2 @3k rpm. Success!
The peace of mind provided really is the best thing of all really.
I plan to install a Gammatronix 5mm LED
volt meter to monitor the charging.
I might update the install on the forums. I supect that I might be able to install it on the dash without cutting as its mounting footprint is 65mm and the dash's push rivets mounting hole actually measures 60mm...so perhaps a friction fit might work.
So far been 120-130kms since the stator and R/R change, no problems!
Thanks again Onewizard!
Sorry for the lack of photos, did not document the process, but I will photograph my current connection and share.