I posted this to the Diesel Motorbike Yahoo group, and wanted to post it here, so if you read it there, please excuse the double dose
I've been down about the lack of charging ability my 10hp
clone engine offers. For several years, I've had a Boyer single phase regulator/rectifier sitting in garage that I originally bought for my '99 Enfield Bullet 500. When I sold the Bullet, I kept the Boyer unit for future needs.
Well, today, I put my bike up on the center stand and did
some checking to see what the stock regulator (Chinese unit) was putting out. After starting the engine, I checked the single phase a/c and it was putting out around 15 to 20 volts at idle and even with faster engine speed (not full throttle). With the regulator connected,
I read 12 volts, but discovered that reading was because the positive lead out of the unit is hard wired to the batteries positive terminal, so I don't even know if it was working. Next, I swapped the stock unit with the Boyer and before hardwiring it in, it put out 15 volts at idle, but the a/c wires going into the unit got pretty warm quickly, so I shut the engine down and got it all wired into the system for a test drive. All went well and the wires didn't burn up. I ran with the head and tail light burning and there was no problems. The Boyer unit got warm (no cooling fins like the stock unit) and the wires were a little warm, but nothing hot.
My head light is 55 watts, tail light around 15 watts and thats it. I seldom use the brakes and almost never
use my horn, so I don't feel I'll exceed the Boyer's 180 watt maximum output.
Does anyone have an opinion about this conversion?
I'll continue to test the unit and measure for battery voltage drop....reporting back my findings
Cris
Pulled up to the window and finally some chic came over to help.... When she keyed up her microphone and speaker, boy did she get an ear full of clatter and racket, poor thing couldn't hear a word I was saying (she looked disgusted), finally, I motioned to my debit card indicating she could get my name from it and sent thru the drawer. Didn't have to answer their normal questions or even sign a receipt, she just gave me my script and off I went 
I've read a lot about wiring upgrade kits, etc. for various bikes where riders want to see at night (or be seen by cager's). Problem is heat and the melting of connectors, and second, crappy alternators that come on most bikes. Honda Goldwings are famous for burning up main stator connector and stator itself ($$$$$$). Some bikes even sport a separate a/c lighting coil to support the headlight on its own. Best system (IMHO) is something like the kits offered for older MotoGuzzi's where they mount a small Japanese car alternator on top of the engine and drive it with a belt. These systems seem to go a while before roasting the alternator (engine heat). You might want to try an 80watt head lamp and see how the system holds up.