I know there are 1000 threads about this and I've read many of them, but bear with me.
Last summer my OEM voltage regulator/rectifier went out, I had the instrument cluster shutdown condition and my low beam headlight lamp blew. That caused a good panic attack, but after calming down and reading through many similar threads on this forum, I determined it was the R/R and replaced it with the uprated Electrosport version. All was well until a few months ago, on cooler mornings I would see the gauge cluster flash off and on near the end of my commute to work (about half an hour, mostly at highway speed). No other issues besides my anxiety at making it to my destination. The bike keeps running fine even when this happens. Everything would be fine on the way home in warmer weather, and throughout the summer things were fine, again on warm days.
Now that the weather is consistently cold, I'm seeing this every day near the end of my rides (after the engine has been running at 4000+ rpm for 20+ minutes). When I see the gauge cluster flash off I flick on the high beam and grip heaters which consume some voltage and mitigates the problem somewhat, but I still occasionally have the cluster on/off flashes even with that, and sometimes when the cluster is off for more than a couple seconds the voltage spikes up to ~17+V on the voltmeter I installed when this issue started reoccurring. I have no other symptoms, no lights have blown out, all electronics seem to work fine otherwise.
I ran the recommended test procedure on the stator to R/R plugs with the engine off and on, the readings looked fine to me but I admit I'm not an expert on that, and did not write them down. I do recall the multimeter readings were even across the wires. I did replace my battery recently which may have made things slightly better but not consistently. Battery voltage is good, approx 12.5V with the key on (voltmeter is wired to the GPS plug so seems to read a touch low), 14.1-14.4V with the engine running, and about 12.8-13V when I shut the bike down. Voltmeter held steady this morning at 14.1V exactly with the high beam and heated grips on max. I can only assume my stator is working correctly but I haven't (yet) opened up the cover for that to see if it's starting to burn out.
Anyway, does anyone have ideas or recommendations here before I start throwing money at the problem? I'm extra confused that this happens more on cold days. I'm less than happy that the Electrosport R/R (which is now out of warranty) may be going out since that was supposed to fix this originally. Should I replace both that and the stator with more Electrosport parts? Should I attempt a mosfet R/R conversion? Do I just add this to my yearly maintenance list?
Thanks in advance