Double check your battery to be sure that you bought the right kind. Also double check the reg/rec. This device is what is primarily responsible for the charging being correct. Overcharging should fall squarely on the shoulders of the reg/rec. if you didn't already replace it with a brand new part I'd still think that was the problem. If you did replace it, I suppose it is possible for your alternator to be broken and producing an absurd amount of energy, but I doubt it.
SOURCE: 2002 suzuki intruder vl1500 not charging battery
Check the voltage across the battery with the engine running - it should be greater than 13.5V.
If less, then you have a failure in your charging system, either the stator and/or the Rectifier/Regulator.
See this personally authored diagnostic guide on how to determine which part is defective. Also has a recommendation for excellent replacement as opposed to std OEM.
http://www.triumphrat.net/speed-triple-forum/104504-charging-system-diagnostics-rectifier-regulator-upgrade.html
SOURCE: Suzuki intruder 1500 charging system
You need to buy a volt meter and set it on 10, or 20 v-. Start the bike and see what it says. A good charging system will show 13-14+ volts. If the meter says 11-12 volts or does not change, you have a bad stator, or rect/reg. Take to a shop to have it further tested. Chaz Moto DC
SOURCE: Rear tail light does not turn on.1998 suzuki 1500 intruder
It mught be the bulb that needs replacing or else check the wiring to the bulb for continuity in case there is a broken or snapped bit.If you have a voltmeter then you can test the voltage reading at the point of contact..Sometimes rust builds up and a simple cleaning would solve this.Hope this helps.
SOURCE: 2004 Suzuki VL1500 Intruder LC Motorcycle backfire
If they cant duplicate it your good.Usualy with backfiring i would make sure to eliminate any exhaust leaks. The dealer is inexperienced at solving compound problems,(sorry) not picking a fight, but sometimes cleaning is not goog enough,I went through this with a 1400 Intruder.several attempts were needed to get the two carbs level on the same line with each other.so the floats would work properly together,then set fuel flow and the air flow through the ventouri in the carbs.Also i had to make these adjustments while level (not on side stand) The floats were very sencitve to needle valve to seat adjustment(bent to open or close some of the flow)
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