Turbo Seca Hot Regulator

I have an 82 Seca Turbo and I've been trying to get back on the road. It's almost there, starts easily and sounds good in the garage. I'm having a problem with the charging system that I think is the regulator but I've replaced it once already (used) and it behaves exactly like the original. The white wires from the stator and the regulator itself are getting way to hot.

When the bike came to me the original regulator connector was melted and someone had done a hatchet job on the wiring with spade connectors, extra wires and electrical tape. I cut that all off and redid it with more spade connectors just to tidy it up a bit and get some good clean connectors in place.

I believe the battery is good, holds 12.5v and has no problem starting the engine.

The stator seems to be good. With the engine running and the white wires disconnected I am getting 40vac measuring between the white wires. At the battery with the engine running I am getting about 13.5v so it is charging some.

Using the test procedure in the manual that I have the rectifier seems to be good and all diodes check good.

I have battery voltage on the brown wire to the regulator and <1.8 to the green wire. According to the manual the voltage on the green wire should go up as the engine is reved but mine goes down? According to the manual if the green wire voltage doesn't go up the regulator is bad. I replaced the regulator with a used one and it behaves exactly the same way. I don't mind replacing it again but am I just chasing my tail here or what?

 

Have you checked the rotor yet. The symptons you describe indicates to me that there is a short in the rotor. The resistance across it should be between 2 and 4 ohms, check the book to be sure. Ohm the 3 wires from the stator, they should be 0 ohms between each wire and open to ground(metal case).
While you are in there how are the brushes?

 

Just pulled the cover and the brushes look good and the slip rings are clean and shiny. Manual says it should read 4 ohms at 68 degrees. I've been running the engine off and on all day so it's more like 150 degrees and I have 9 ohms. It doesn't seem to be shorted and it's not open so I think it's okay but I'll have to retest after it cools off. The stator tests good with an ohm meter per the manual.