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Awesome information! Thanks for sharing. Have you had any success repairing the old regulators?

No I haven't tried. I think there are too many parts that would have to be replaced... basically everything except the resistors.

That one was taken apart by someone else. He emailed me because he wasnted to build a new one based on the old design. But with the sequential shunting, it's not feasible since the later alternators don't have color coded wires. Plus, at a little over a hundred bucks for an aftermarket one, it's not worth the time and parts cost.

However, with all of the troubles you and KZ_Rage have been through, I may start to tinker with the design I made many years ago. Or, I might try OregonMotorcycleparts.com the next time I need one.

I know this is an OLD thread but I had to reply... I HAD the exact same problem. Turning the key off would not kill the motor. Turning the key off only made it run like crap AND with the key off I could kick start the bike - just like you described in this thread. Turns out, someone had installed what looks like the same R/R in your photo (3 yellows, a black and a red wire connected to the brown – all plugged into the green connector). I cut the brown loose and connected with the white/red that goes to the battery, and FIXED it! My guess is, the original install instructions were flat wrong or too confusing! I had to re-read this whole thread - the last time SLOWLY and boom! That was the trick! Thanks guys....

Awesome! So glad you found this! As you can tell from the thread, it took me quite a while to figure it out. I still can't believe that happened. Like you said though, makes me wonder if the instructions were wrong or not very clear. It's probably happened more times than just these two. I love this forum!

Just thought I add one more interesting bit of information. Again from what I can tell, my wiring was done (incorrectly) just like yours. As it turns out, that brown wire the red (charging) wire WAS connected to, runs out of the back of that green connector over to the brown connector on the left. Well, that runs directly to the tail light (brown) lead wire. THAT means for some time, the battery was being charged thru the tail light circuit! Mine was BADLY overheated and melted throughout the wiring harness. Had to replace it all the way into the head light bucket. Even the white 6-wire connector was toasted. After I replaced the brown wire completely, all is well. Needless to say, RED wire of the R/R to the BROWN wire is horribly WRONG!

So if you are reading this thread and have this same wiring problem screw up, CHECK YOUR WIREs!