Charging or battery fault.

[Crash Bandicoot]

Now before i start properly let me just say that I am well aware of the other threads concerning electrical faults, but as of yet my electrical fault hasnt fallen into any of them.

First off: The bike is a SV650s 51plate curvy. 21k on the clock. full annual service history. I have owned it for about 9 months.

Fault free riding for about 6 months then I noticed that the bike wasnt charging its battery when running. Okay... That sounds like the old reg/rec issue... Tested it all, and had the local garage test it... came back fine, working like new.
Next step: battery. New one in, worked fine for a few weeks, then went to restart the bike at the gas station and nothing.
Okay, generator. Had that tested and sent off for recoiling. Came back as new. fitted and went over the whole bike with the mechanic to check the wiring. all fine. Works for about a month, then restart my bike outside the garage to put it away after a 40mile motorway blast. Nada. No charge.
Back to the garage again... Initially dropping about .5v over the first 10 mins, but after warmed up... working fine, charging fine. after the initial trouble and multiple restarts, no drop in charge...

Any ideas how to locate this niggling fault? So far neither I nor the local garage has had any success.

Any help would be hugely appreciated.

Thanks

[tigersaw]

did you try moving the handlebars lock to lock when testing, in case of cable chafes?
All connectors in charging circuit in good clean shape, no sign of fatigue or overheating, all well mated?

[Crash Bandicoot]

no apparent cable chafes and all the connectors seemed to be in good condition.

A possibility suggested was the lack of any damping between the exhaust and the frame, since I swapped out the stock passenger footpegs for a simple hanger a few months ago... Could it be the vibration shaking connections loose (although none have been found)

[andrewsmith]

Have you checked all the contacts for dirt and rust etc...
as is sounds like the mouldly green connector behind the headstock

[Crash Bandicoot]

to tell the truth iv been concentrating towards the back of the bike... ill have a look at the mouldy green connector when i pick the bike up tomorrow...

Has anyone else had one of these electrical faults that turned out not to be gen or reg/rec?