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Unplug the stator yellow wires. Start the engine and check the ac voltage across each pair of yellow wires, a total of three tests. While checking the voltage raise the engine rpm. The ac voltage across each pair of yellow wires should exceed 50 volts ac when the engine rpm is above 2,000.
Yes across each pair of yellow wires. that current leakage is normal.
What is the ac output across each pair of yellow wires at idle and when the engine is reved up?
Does it ever exceed 59 volts the higher you rev it?
Sorry, I misclicked. Does it ever exceed 50 volts ac when you rev the engine.
It should go above 50 volts ac when you rev the engine higher and I believe it will based on the numbers you are getting now. Most likely the regulator portion of the regulator/rectifier is bad. I saw one of those a couple of years ago that had the regulator/rectifier replaced twice on it and the customer kept coming back saying the battery went low after a long ride. We ordered another new regulator/rectifier from Honda and when it arrived it was a different part number that was superceeded. After installing it the battery charging voltage was higher than it had ever been and the bike never came back. So I suspect replacing the regulator/rectifier will fix the problem.
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Hi Colby and welcome to JustAnswer,Thank you for the relisted question and your patience. Should you still need assistance for information purposes only...Initially, appear to be several potential issues.
Still, let's review what we know and compare with the basics of this model. Then, proposed preliminary tries (if have not been done):
If the AC output of the stator is uneven, then the stator would be suspect including its wiring and connectors.
For Hondas, normally harness green wire to chassis ground starting with the headlight, brakelight and to include regulator.
Then a ground strap from the engine to the frame then to the battery's - terminal.
The additional ground line would serve as both an attempt of a fix and as a test by process of elimination.
IF with good ground, wires & cables, connections, loadtest passed battery and known to be good regulator, there is still a charging issue, THEN the stator would be the only suspect left.
Also, hardwiring a secondary ground line is the easiest to implement not only good practice considering the age of the Honda.
From the battery's - terminal to the frame and then another from the battery's - terminal to the engine.
The bigger the better but even a #14 would do the job since it is meant to be secondary.