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how hot should this get when the bike is running.mine gets mega hot, i mean, you can't touch it, so is this right or wrong, could this be the hot start problems?

It's doubtful.

The regulator/rectifier unit turns excess power from the generator into heat to disperse it, so it should be getting hot - but it could also be a sign that it's on it's way out...

There are quite a few tests you can do on it, but you're better off in the Technical Section for that stuff!

have u seen the tests? u need 3 batteries, cheaper to get another reg/rec.

hello i have just started getting a problem with the battery becoming flat over a couple of days on my bike, with the engine running and revs raised i only get a max of about 13.5v over the battery which seems a bit low to me as battery has 12.7v with everything turned off.so i took a look at my regulator i found mine to be extremely hot as well i couldnt even touch it, i no it disperses heat but the bike had only been running for about 2 mins.once it cooled down i took it off and looked at the wiring and connector all look ok atleast.
i found a table on section 15 - 15 in electrics in my manual to check the resistances over the regulator with it off the bike (as i dont have 3 spare batteries to test it and dont want to waste money just guessing what the problem is)
anyways it tells you to check the resistance but i just did a 'diode' check with my multimeter (so it 'bleeps' when you make a circuit) and when i touch BK/Y and Y1 together it 'bleeps' to say its a completed circuit and when i check the resistance over those pins the resistance is 0.
just wanted to check with some one that might know and to help anyone else out with this problem........i think this means my regulator is knackered right? as this should be open circuit with infinate resistance if i read it correctly.any help would be great thanks

hello just an update, got hold of a second hand regulator and did the same continuity test on it as the old one and all the pins are 'open circuit' as they should be and now the bike charges at atleast 14.5v at idle and doesnt get any where near as hot as the old one used to.
just thought i would let you all know.

Have got a zxr400h 1989-1990 model & the rectifier has 6 wires leading to it 3xyellow 1xblack/yellow 1xwhite 1xbrown & the previous owner has cut off the plug connector & wired a non-standard rectifier to the bike which is now causing the engine to cut when hot.Would anyone please be able to help me & provide me a photo showing where the rectifier should be mounted as he has positioned it on top of the rear mudguard under a single seat unit(no air flow to it at all)also the connecter into it so i can see where the wires should go & in which order into a standard rectifier.You would be helping me massively thanks karl.

Could anybody also post me a photograph of the 6 wires that go into the snatch plug that goes to the regulator?

Any help would be much appreciated.

thanks again.