The regulator part works by short-circuiting the excess voltage... anyone who's ever short-circuited something 12V by mistake (or even on purpose! ) will know how quickly the wires or component gets hot and eventually melts, or even explodes... allegedly!
The reg/rec is squeezed into a very compact housing, and the rectifier components themselves also generate heat while converting the AC generator current to DC. Both parts are generating heat as soon as the motor is running, which is why it gets very hot, very quickly, and why it needs a good heatsink and preferably unobstructed airflow around it.
There's a surprising amount of energy that comes out of a small motorcycle stator.
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Andy.
NSR-WORLD.COM
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