b171doc, Start checking all of your connectors. I had a similar problem and ended up cleaning every connection on the bike to fix it. HINT: There are a ton of connections located inside the headlight basket behind the lens. Also, pay close attention to the ignition switch connector and maybe even the ignition switch itself could be bad. You mentioned that you measured 11.6v at idle. That is not out of spec. Mine does not get over 12v until almost 2000 RPM.