Just had a friend round with volt meter to check wiring etc and this is what we have come up with.

Resistance across all pairs of yellow stator wires approx 0.4ohms all equal
Voltage across all pairs of yellow stator wires approx 25-30v ac when revved all equal

0 ohms resistance from red @ black rectifier wires to battery terminals live @ earth

Battery terminal voltage

Engine off 12v
Engine on 13v
Side lights on 12.5v
Main beam on 11.9v
High beam on 11.3v All at 4000 rpm

Yellow stator wires get very hot within minutes and connector had burned black

Hope this makes sense

Any suggestions
Cheers Kev

Thats a very common problem on early fireblade looms 3 yellow wire connector block has very high resistance and burns
CURE- Cut it out and replace with new connectors

Thanks, will try that tomorrow

i had same probs using original bike reg/ rect as it cant handle the extra power drain & either the wires burn up or the unit itself fails, upgrade to 1000rr with a small PC fan blowing across it

[Edited on 11/9/11 by andyfiggy2002]

Thanks Andy, will look into giving that a go

Any particular year for rectifier or will they all do the job

got mine from the BEC maestro andy barnes from AB Performance, do a search on google & give him a bell

Cheers, will give Andy a call tomorrow

The newer ones use mosfets, whatever they are, and are much cooler running and stabilise voltage much more efficiently apparently.