We know the voltage will increase with RPMs. Nothing new here. If we assume that the regulator is in the correct yellow circuit (from the stator), the only thing left is the unit itself.
It's not a matter of current, the problem is excess voltage. If you have a big enough load on the sytem, you can pull the voltage down. This isn't much good because a high wattage bulb will barely glow at idle.
That makes me believe that the regulator itself does not have the capacity to clip the voltage properly. As I recall Rubber Johnny used an aftermarket regulator and still had some trouble. I think his issue was mostly a bad ground so the regulator was not in the circuit.
If Jake tries the 2010 regulator on the newer bike that might tell us if the unit has changed. If there is no difference, has the stator been changed?
What about the frame construction of the newer bikes? Is there a ground path problem? Was the ground better on the older bikes because of the head stays?
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2011 EC250E
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