Voltage Regulator/Rectifier

The cop bike has a plug panel under the left side cover, right? If the folks who did the conversion buggered up the panel wiring, then it would require some work to straighten it out. If I had a cop bike and it required "complete rewire" because of hacking, I would just contact a friend and get both the right and left switchgear, the headlight harness, tail light and main harnesses from a donor bike with that bikes plug panel. The only thing that would be tricky would be the gauges... you will have to do some figuring to make the idiot lights work using your old gauge mini-harness. With this stuff in hand, it would only take a couple hours to rewire the bike. The tricky thing is matching the switch gear connectors to the harness and if you get them from the same bike, it makes it a snap... if not, you need to understand where the wires go and why and then make new connections. If you need help with this, give me a holler.

Aye the plugs are under a panael onthe left side. There are several places where things have been cut out and wires have been soldered together to complete a connection. I spent the afternoon toning out wire leads and I might as well be trying to find the end of pile a noodles. OK here are the readings for the battery with the new reg/rec plugged in and getting awefully warm. At idle Im reading 13.3-13.4 VDC and when I rev it up to 3500 RPMs It jumps up to 14.2-14.4ish VDC. Now the wierd thing is when I let off the throttle it doesnt go back down. Just sits at 14ish range. Just an FYI the wires that are getting hot first are the ones comming from the harness/generator and then that carries over to the new reg/rec. So technically it IS charging the battery Im just worries that its getting very warm and I dont wanna blow out anything of course that IS why I have fuses. I also dont want to melt any wires so thats why I ask if its suppose to get hot. I knw the reg/rec will get warm thats why it has fins and is made of aluminum (heatsink) its not the reg/rec im worried about. Note to anyone out there interested in buying an old cop bike. Be warry, they CAN butcher wiring.

Glad I did a search and found this post !
I to went outside yesterday and checked my charging voltage since the bike been cranking real slow. Bike was only showing battery voltage. I did a test before the battery went dead from having the harness disconnected and Im 90% sure its my regulator that went out. I did get 25 volts on all 3 yellow leads before the bike went dead. (only had it up to about 2000 RPM) I went and bought a 5 wire replacement and was also worried about the brown wire not being used. I have it all hooked up and Its a bigger unit then the original. The dealer said this is a much better regulator thatn stock. He is the KZ specialist near me so I will find out. I mounted it near the fuse box for now, over the winter I will mount it under the battery tray like it should be. I really hope its just the regulator and not the stator. The battery is charging now so I will find out in a few hours and post back.