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Hello, after changing the reg/ref and doing checks on the battery (14.4v on charge) and the impedance of the coil (1.6ohms on any pair) I am stumped.

All are within the the service manual but yet the casing is as warm as a downpipe and my foot is cooked with my boot feeling like its been in the oven?!?!?Can not think of the problem, Any thoughts??

Have you given the thermostat a going over? By that i mean checking its working properly? How warm is the radiator?

Hello, yes have checked the whole cooling system. Fan , fan switch and thermostat are all within service. The gauge reads about halfway when riding. I will check how warm the radiator is next time I ride.

The gen/alt casing is about as warm as a downpipe ie: too hot to touch and stays that way for a long time after the bike engine has cooled, poss the oil keeping the coil warm