Join Date: Aug 2005
Location: Orangeville, Ontario, Canada
As Exavid and Twisty have stated, I would verify your battery at this point and all electrical connections, it sounds like the battery is getting hit with higher pulsating DC and is acting very much as a capacitor with accepting and discharging of electrons. Your reg and its zener diode will limit the output voltage from the alternator and I will accept that, since you have replaced it. Verify the ac voltage on the alternator is equal on all 3 lines, get help to hold the meter while you read it. Label the leads A,B and C and read the voltages at the same RPM steady A to B, A to C and then B to C. You may also have a diode shorting on one side of the full wave rectifier.But I still have to agree with the gurus that a check of all connectors especially grounded connectors. With poor ground conduction your system will provide grounded voltages above or below the nominal 12V , especially since the alternator has a floating neutral. All connections must be clean, use contact cleaner or brake cleaner, blow dry, put them in and out 3 times and do not use any grease at all, to seal up, especially while you’re diagnosing the problem. Remember at 300-500 watts, the electrical system will always be warm to hot to the touch, especially the crappy and dirty joints since amps will be flowing all the time even if everything is off since the alternator will be dumping the excess to ground and that grounded connection must be good, clean and tight. At 12 volts nominal, the complete system, every joint, every connection needs to be good and clean otherwise the dirty connections will impede the flow of electrons in every possible manner, making troubleshooting a nightmare. The easiest thing for you to do and without any electrical knowledge is to do housecleaning. Tools required: Hands, eyes, contact or brake cleaner, small brass brush, small tooth brush, rags, compressed air, possibly a metal pick, PATIENCE.
Above all SAFETY GLASSES, NO SMOKING, REMOVE THE BATTERY AND CHARGE IT SLOWLY TO FULL FLOAT AND A NOW $8 HYDROMETER TO CHECK THE BATTERY. BE SURE TO VERIFY THE BATTERY VOLTAGE BEFORE INSTALLING. NEED HELP ASK!