TechAdmin;
I sure wish I had that here! I would grab the output(s) of the stator; let the bike run to make sure the outputs aren't fluctuating due to heat related issues. The do the same for the regulator.
Having the 3-extra windings could in theory cause a over-voltage issue, right along with heat related issues.
I would all but bet $$$ it's a combo issue, but would lean more towards the regulator.
Sorry, but I'm working on a raid 5 issue right now and can't go back and re-read if you replied with the Specs of the regulator.
Could you post those PLZ, if the stator is now outputting too high a voltage, it'll throw the regulator all out of whack.
Battery charging, regulators are supposed to bring the voltages up to a 13.8~~ along with high current (BUT you already know this). I have actually seen 160A alternators output 14.5Vdc to the battery just trying to check it up where it regulator wants it to be.
SOooo;
When you have the time, check the output voltage of the stator going into the regulator, see if it's above specs, if so let the people you got it from know this. IF it's in specs, leave it run until it gets heated up and see what's up with those voltages again.
It does at first appearances look okay, but one never knows.
IF it's playing nice nice throughout , then possibly do the same with the regulator.
I actually love, love , love getting these kind of problems. Keeps my troubleshooting skills tweaked
Sorry if all of these steps have been done.
Did I say a Dell R720 and be a real &^%^(*% !! ??
Cheers
Bruce S