You're all seriously helpful guys :)

It seems though that it is all working as should, I have covered around 30 miles today and yes the rectifier is stupidly hot, but hopefully it lasts me the next week then I can do something better with it when I'm home. Maybe I should hang the rectifier outside the fairing and that will cool her haha

What were the battery voltage during the operating settings listed in my earlier post.

Does the rect/reg make perfect contact with the chassis mounting plate. Also heat transfer compound should be used between the mounting plate and the rect/reg metal mounting surface. Any assistance in transfer of heat from the rect/reg to the chassis is a good thing.

magg wrote:What were the battery voltage during the operating settings listed in my earlier post.

Does the rect/reg make perfect contact with the chassis mounting plate. Also heat transfer compound should be used between the mounting plate and the rect/reg metal mounting surface. Any assistance in transfer of heat from the rect/reg to the chassis is a good thing.

We gave it a quick blast to see if it was doing the business last night, although I didn't record anything, I remember seeing 14.7 at 5000rpm with no headlights.
With headlights it only dropped slightly at this RPM, down to say 14.3. i then dropped it to tickover with the lights still on and I think it dropped to a low 13. Having said that, my tickover is abnormally high at 1900 RPM.

That's a good popint I could do with mounting the rectifier properly..