I have had $400 Flukes read wrong because the leads were damaged..always check your meter.

 

I was having the same issue so i replaced the regulator and nothing changed. Resistance readings were good at the stator pins with no shorts. This is what i found. I thought the magnets were suppose to be attached to (and spin with) the rotor?

 

And.... What was the AC output of that mess?????

 

A/C output maxed out about 36

 

Amazing!!!!
Still should have charged just fine then!!!! Ac is AC... the regulator don't care where it came from!!!!
Maybe centrifugal force kept the magnet unit in Place??

And I thought I might Prefer the Encapsulated magnet type rotor!!!!! Maybe not!!!

 

From what i can see, the only thing suppose to hold it in place is a tiny wrist pin and (180* out) a spring. Magnets are still good and strong, stator still has no shorts. Half tempted to put it back together with some gorilla glue but I've already replaced the charging system.

 

LOL
I'm half tempted to have ya send it to me... I'll put it on a "non critical" Bike and see just what comes of it.... But, I ain't young anymore, and do Not take 'em apart "just to see" anymore either!!!! Very Interesting just the same!!!

 

We tried the regluing with an industrial 2 part epoxy on a broke *** buddies bike, worked for a while till he scrounged another. The repaired one was giving out again, that thing gets hammered when you think about what, where and the environment it works in.