Motorcycle Repair: regulator recitifier, continuity check, butt connectors

Question
1995-Honda CBR 600f3
I put a new voltage regulator on about four months ago, the other one had gone bad and melted the wiring harness at the regulator.  I put the new one on by crimping on butt connectors on the three yellow wires and the green and red one. On the way back from a long ride to bike week a few weeks ago the bike did the same thing it did when the first regulator went bad (sputtered a few times kind of like it was running out of gas and then just died)the wires going to the regulator looked like they got hot again but were not melted.  I'm in the process of seeing if this is a warranty issue with Dennis Kirk because of a bad regulator.  Could there be something else wrong causing me to burn these regulators up and if so how can I trouble shoot that problem.  Thanks for any help you can offer.

Answer
Hi Jaros,

Check the output of the alternator "output test."

Check alternator winding for resistance and continuity.

Check all multi-connectors (electric plugs) for corrosion. Put dielectric grease in both sides of each connector.

The solderless connectors used to connect new regulator may have caused too much resistance. Try different connector or replace with factory multi-connector.

Need electrical test how-to information? Send me an email address as requested.

Respectfully,
Mark Shively