I have already followed the testing procedures to determine that the original r/r was defective, and that the stator was okay. In fact, all three leads were putting out over 70 volts at 5000 rpm. When I got the new regulator, I tested it per the diagram in the stator papers, and it passed all the regulator tests.
I attached the new regulator, making sure the connections were tight and that the grounds were good. At idle to low rpm, the bike produces normal voltage, but as I rev the engine higher, the voltage rises to a peak of 16 volts. None of the connecting wires get warm, but the regulator itself gets warm to the touch in 1 minute, and hot to the touch after 2 minutes (in the garage with no airflow.)
I am wondering if the voltage peak could be a normal condition, perhaps if I had a poor battery? What else could cause the voltage to go high? I hate to think I wasted my money on this regulator, but it was about 1/4 the cost of a new one. If this doesn't work, I'm trying a honda...
I am using a good quality digital multimeter which is performing normally. I do not question its accuracy. When I tested the voltage drop on the positive and negative wires to the battery, the voltage level was supposed to be below 0.2 volts, and mine was about 0.01 volts, so I think the connections are secure.
Please help if you can.
Matt
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