ZXR250c charging system

I've got a strange problem with the charging system on my zxr.
Firstly, it's a brand new Motobatt battery, the loom is complete and has never been hacked into. Battery voltage is just over 12v (12.2v) and at 2000+ rpm it's got 12.8v.
I noticed the rectifier get pretty hot when it's running, I've tested the three yellow wires as pairs for input balance and there is a slight imbalance but nothing major.

Has anyone had charging problems, and wat did you do to test the system.

Here's a pic of it just for fun....

 

I had rectifier problem on my 600, earthing is critical in charge systems, I spliced into the earth line at the rectifier and added (3) additional earth's, 1 at the rectifier mount, then 1 at the engine case rear, then 1 as close to the stator as possible. my charge volt returned to 14.6 v, perfect. hope this may help.

 

thanks for the advice. from what I've tried it looks like the rectifier is dead.
This brings me to the possibility of fitting one of a Yamaha R1 (mosfet style)... as anyone had a go at this and what were your results like?
Also, has anyone tried this CDI? http://www.aliexpress.com/item/Digital-electronic-CDI-for-KAWASAKI-ZXR250/538059961.html
I thook it for it first ride today since rebuild (also first time this bike has seen New Zealand roads!!) and over 10,000 there was a misfire. Either bad coils or something, it only came on when loading it in high gear from 100km/ph+

 

Just an update.
I installed the mosfet regulator (YZF-R1 one) and it works perfect. It only uses 5 wires so you do have one (brown colour) wire left over on the factory loom. It also bolts directly to the original mounting point.

 

Can we see some pics ?

 

Yeah man I get some pics. It will be in the weekend because the bike isn't where I live... My workshop is on the other side of Auckland lol.

 

are you sure its misfiring, one time i didn't put the carby's back on properly and had a huge leak with them symptoms, wouldn't rev over 10k.

 

It's revs up to 1650 but no further. I drilled the main jets out to help after putting the new exhaust system on. But I think I drilled a "wee" bit to much... I'm going to try get it running perfectly tomorrow.

 

Charging system works great now. The battery was dead flat so I had it on a charger for a few hours...
I'm STILL having fuel problems tho.
I've balanced the carbs, set all the idle mixtures, balanced the floats, rejetted the main jets and also drilled extra bypass on the CV slides (that actually gave it noticeable throttle response gains) it's not revving cleanly past 16500 but runs great under 9K

 

check all vacuum lines and carb boots.. do the revs hang when its in neutral and raise the revs?

 

The idle doesn't come down after a rev very quickly, it does linger a bit then fade back to 700rpm.

 

Running lean or you have an air/vacuum leak if the revs hang when you're off the throttle

 

Sounds like an air leak to me.. @Th3_Huntsman has had plenty of experience with these bikes... he could help.. most I would say is spray some WD40 or inox around the carb boots and see it it raises the revs.. if so carb boots are leaking air..

 

I'll give that a go this weekend. Cheers

 

Not a problem.. That's what we here for mate..

 

i had the same problem mate, 16.5k and above wasnt doing much, i just changed all my vacuum hoses and cleaned up the carby boots and it went nicely after that, supercheap has the hoses should be 10 bucks all up.

i noticed tons of fine hairline cracks in my hoses most likely because they are 26 years old.