Glenn, on the Kuga, is the battery light on all the time once you start it, or does it go off then come back on after a few seconds? If it goes off and comes on after 20-25ish secs , it points to a fault in the smart charge circuit.

On the old Kas they had a fuse for smart charge above the fusebox that was easy to miss.. Might be worth checking all the fuses at least!

Haven't seen any probs with the Kuga ones yet but first time for everything!