My factory battery would no longer accept a charge. So I went to auto zone and purchased a replacement, followed all the charging instructions. It started great but after riding for a while the battery bubbles and then overflows. I took the battery back and got another one but it does the same thing. Anyone have any ideas what could be causing this? Just crappy autozone quality battery or possibly a electrical problem?

 

Sometimes the new battery needs to be charged before the first use.
If you have a digital voltmeter, monitor the voltage at about 3000 rpm. It shouldnt be more than 14.5 volts.
Whats the brand name, of the battery? Is it a direct replacement, for the oem?

 

After all that engine work did you buy a bigger battery or are you still running stock size?? I had some starting probs with my Rappy cause of the high compression so I switched to the stock Grizz battery and no problems since! It fits in the Rappy battery box too, you just have to remove the foam. Good luck!

 

It sounds like it's over charging. Do what hondabuster said.

 

It is a magna power from autozone, and it is supposed to be a direct replacement. I am going to go get a voltage meter and check it out. Thanks for the replys.

 

I went and got a voltage meter and it is definitly overcharging. The meter went up to 16 volts and it was pinning the meter at an idle. Do you guys think it is the voltage ragulator or is it something else?

 

That would be my guess.

 

The voltage regulator is over charging.

The charging spec. is 14 volts @ 1000 rpm. The proper charging target voltage of a wet cell 12 volt lead acid battery is 13.5 volts to 14.00 volts. When the voltage climbs over 14.5 volts it boils the water from the battery. Much like a pot full of boiling water, it overflows, and that is what you are seeing here.

Before you go and replace the voltage regulator you may want to check your charging coil.

Disconnect the AC magneto coupler fromthe wire harness.
Connect the pocket tester (Ω × 1) to thecharging coils.
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 2
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 3

Measure the stator coil resistance. Charging coil resistance: 0.32 ~ 0.43 Ω at 20 °C (68 °F)