Motorcycle Repair: yamaha fz charging/ignition, rev counter, weird one

Question
Hello again, I refitted the old regulator and the problem is still the same, the voltage over the battery is now 13.8 volts. U have taken some current readings, without the alternator connected but ignition on 0.57amps draw on battery, with alternator connected 3.3amps draw. With the bike running 2.68 amps draw without alternator connected, 2.5amps going in with alternator connected, but the alternator casing is becoming untouchable due to heat. I have noticed if I run it to use the battery a bit before I connect the alternator then the rev counter takes longer before it faults again. When I run it with the lights on then the revs can build up to 8-9000 rpm before the needle shows signs of flickering and dropping to zero, and the current reading shows 3.5 amps going into the battery, but the alternator casing is red hot and untouchable, regulator is red hot and the red wire is also getting quite warm, but if i let the revs drop with lights on the the battery starts to seriously discharge and stop the bike. I hope that you can put a finger on it,cheers!-------------------------
Followup To
Question -
I have a Yamaha FZ400r 1984 jap home market (46X). The problem is when I connect the regulator(which is a new one) the bike's rev counter drops to zero and the bike won't tick over and won't rev cleanly sometimes running onto three cylinders. I can check the battery voltage and it is ok at 14.3 volts,charging coils ok at 0.7 ohms and 40 volts ac each, and not earthing. Brushes are ok (one slightly longer than the other but free and not to earth), the rotor is showing 2.9 ohms and not to earth. The red wire from the regulator will start to heat when this is happening. If I put the lights on when the bike is running it seems to help the running of the bike and intermittently brings back the rev counter. Have you any ideas!
Answer -
Hi William, thats a weird one. I am just speculating of course but it seems that maybe your regulator is faulty, even though it is new. If the old regulator is installed the problems go away but the bike doesnt charge probably. I would have to suspect the new regulator is faulty. You didnt give me a DC amperage reading at the battery when the bike is running. It seems to be overcharging. 14.3 volts is high if the battery is in good shape. You also dont say if the bike has the rectifier built into the regulator. The red wire from the regulator is heating up due to an overload of current {Amperage} the lights being turned on increases the overall load {Amperage Draw} and diminishes your overcharging problem. Being that this is a gray market bike {at least in the US} are you sure your getting the right parts for it? Let me know what you find out
craig

Answer
Hi William, I am stumped. Without actually being there to run tests in person I am afraid I am not much help. Just guessing I would have to say it is still overcharging on the amperage. I would have to have the bike in my shop to assist any further sorry.

randy