I'm kinda double posting here, but as this is sticky post and many people may be wrestling with the problem I hope nobody minds me adding this here too

I had the the bad connection issue with the reg last summer. I sprayd the connector with WD40, dislodged a tiny piece of plastic that I found inside the connector and put it back in place. Had no problems until this week.

The LED that I have installed on the dash luckily shows immeadiately when the battery is not being charged while the bike is running so I no longer get left on the roadside. I highly recommend installing one for peace of mind. Cost only a few euros and is easy to plug in straight to the battery. As I said I ran mine all the way to the dash so I can allways see the battery is being charged & ok while riding. Gives you some time to react if there is a problem.

Wigling the connector plug a bit currently solves the problem . I just put the bike on idle and wigle the connector and push it "deeper" until the battery charge light turns green and off I go! However, I'm having the whole wiring loom replaced in few weeks. Under warranty I might add as I talked to a local shop last summer about the issue and they promised to fix it if it reappears. The bike (09) had about 4000 km on it when I bought it, now it's around 9000 km.

On my bike the problem is not moisture, nothing is corroded etc. and the inside of the connector is dry as a bone. It just seems that the plug is not pushed in enough and kind off shakes loose.

I think a zip tie that pushes the connector and rectifier together might do the trick for me, but as the loom will be replaced I'm not going to bother.