I forgot to post some learnings out of this experience.
- SOLAR BA7 Battery and System Tester. I got a new toy while dealing with this problem from Amazon. This is a tester for the battery based on internal conductivity of the cells, in theory more accurate to gauge the status of the battery than traditional methods such as voltage and load tests.
See more details here:https://www.youtube.com/watch?v=Oi8sUE9XCgA
- Stabilant. This is an interesting product to help improve the conductivity of connectors. Yet, it also helps create a barrier to isolate the connector from the environment to reduce oxidation. Sort of "have your cake and eat it too". Apparently the conductivity is activated by the electricity. More info here.
http://www.stabilant.com/ By the way this is quite the opposite of dielectric grease which is normally used for such cases.
Obviously cleaning the connector with a good contact cleaner (Deoxit D5) prior to use Stabilant is necessary. I'd found that sometimes there are faulty codes in modern bike due to poor connections. And just by unplugging, cleaning and re-plugging connectors is a simple way to solve those issues. Now, I have a better weapon to deal with such events.
- Torque small bolts. The alternator case have small bolts that require only 10Nm (7.4ft-lb) of torque. That's way too low for most meter - even if the tool shows the reading. I have stripped more than one such bolt by using regular torque meters. So, instead of buying a fancier tool which I'm sure there are, I devise my own "home made" approach. I used a bolt similar to the one in question and set it against a piece of scrap aluminum with a nut on the back. I tried several times with the torque wrench set at 10 Nm and measure the angle required to reach the "click" after it's settled against the base. Interestingly the readings went from slightly less than 1/2 turn to just 1/8. No very accurate and probably the reason I stripped those bolts in the past! So, I just used just 1/8 turn after the gasket was compressed and some blue loctite. Problem solved
- "Shop Class as Soulcraft" by Mathew Crawford. This little mechanical exercise remind me of this book. It explains the pleasure of craftsmanship and why is so difficult to find the equivalent in the traditional corporate job. Worth reading.