Azcatfan:
If your sure you need a new alternator, order it from Hitchcocks ! The shipping will be a large number but the item will be in your possession within 3 to 4 days. They airmail everything out side the UK.
Neil and Buzzy the Bullet.
Thanks Neil, that's good to know. I like to buy from our host whenever possible, but in this case they don't show an alternator for my model. Everything they have for an Iron Barrel is the KS model. Thank you for the Info, Hitchcock's has a good reputation too.
Electrical parts wear out period! I wouldn't worry to much on why it wore out unless you think you had done something to perpetuate the problem. These bikes do generate a lot of vibration which can be a killer on electrics. One thing to think about is you are getting voltage, just not enough. Your problem could be that your rotor is not as magnetized as it was when new. An electric motor shop in your area could re-magnetize your rotor for you or you might be able to go online and find a how to video. I would try that before spending the bucks on a new stator. Once you pull your stator and rotor off you can check the rotor by taking a large screw driver and attach it to the rotor and lift it up. If the rotor doesn't stay attached to the driver it needs to be re-magnetized.
The magnet fealt pretty strong actually, even before cleaning it took a bit of force to move the stator around while I was taking it apart. I'm pretty sure that the magnets could have held a fairly heavy wrench if I'd chosen to place one there.
I also agree that the vibes and heat can kill a small alternator like this one, but I figure it won't hurt to go ahead and clean up any other potential electrical problems.
Thanks for all the help!