High beam switch

[darrsi]

The volts were fine with the engine running, showing around the 14.5v mark. 14v to 14.8v would be acceptable with 14.4 being absolutely correct

With all gadgets and lights off it was reading 6amps @ 5000rpm. Most likely because was the battery was partial charged and the regulator was doing its job.

Problem is the manual says it should be 18 amps @ 5000rpm This is the max rating and would not normally be seen under normal operation

Then as you can imagine once i started turning lights on it just kept dropping.  In fact i should've tried it with the heated grips on as well.
With all lights on, including high beam, it went down to a reading as low as 1.5 amps.
Sounds more like a dodgy regulator when under load.

The regulator is the first thing I would change based on the above.

You can test the Generator by checking the AC voltage output of the Generator at the connector between the regulator and Generator.
This should rise from around 20 VAC to 90V plus as the engine revs rise. you will need to perform the test 3 times on the white generator wires across 2 of each of the 3 wires in turn to check all 3 coils of the Generator.

The headlight mod was to bring on the unused dim of the H4 bulb and should have a wire from the H4 bulb coming from the electrical box under the tank and joined to a green wire which comes from the Hi/lo switch. Many were done incorrectly and the H4 dim Stayed on when the H4 Main beam was switched on. This caused poor charging and eventually would burn out the Hi/Lo beam switch or the right side lights on switch.

The regulator was changed for a brand new one a few months back, along with the battery.