Re: problems after changing voltage regulator
 

The unregulated voltage looks OK.

Another couple of test while you're in there;

Can you check the output voltage (DC) across the battery terminals as you did at the start of the thread, but this time with some revs? Check it at 5k revs and also a bit higher as your problem seems to be worse at high revs. It should stay between about 13v and 15.5v.

Also worth checking for a short by doing a leakage test. With the ignition OFF, disconnect the negative terminal of the battery. Set your multimeter to the Amps function. Connect the negative lead of your meter to the negative terminal of the battery. Connect the positive lead of the meter to the disconnected negative lead. You want to see a reading of no more than 0.1mA but set the meter at a high rating initially and then reduce it to the milliamps setting just in case there's a high current flow.

Which connector is it that was overheating? Is it the wires from the generator (the 3 yellow wires) or the output wires? Some pics of the offending wiring might help.

Re: problems after changing voltage regulator
 

hi, just looking in the haynes manual and it says " 70 volts ac " min @ 5000 rpm

Re: problems after changing voltage regulator
 

How have you wired the CBR one up? pics plz :)

Re: problems after changing voltage regulator
 

Tams advice is spot on, i`ve just done all the tests he said when talked through by YC :) Youralt readings are the same as mine are = correct, there or there abouts. My reg rec was down but been sorted by YC with a cbr 600 unit, hope mine doesnt pop in a few miles!!

Re: problems after changing voltage regulator
 

Ain't that strange, I've a Honda Firestorm, after blowing me 3rd reg/rec (which is the same as cbr) have now fitted a Yamaha one, had to rewire connector which basically was just swap the output, had to rewire from the stator to the reg/rec as this had gotten very hot and melted, the best mod is to fit a Mosfet type reg/rec from a Suzuki or Yamaha but the heat sink is a lot larger!!!

Re: problems after changing voltage regulator
 

I wired a GSXR750 one to my SV ... virtually the same wiring system and a far superior reg/rec to the SV one ....