I had the same problem last fall on my 01' ac 500. My measurements on the cdi and regulator were both off as well. I also tried charging the battery while it was still connected. Ended up replacing the regulator since it was cheaper (ricksmotorsports? was mentioned in earlier reply above). They have wonderfull customer service, it was around $100 for the part. That fixed it for me and haven't had a problem since. Guessing that's ur culprit.

 

I understand that due to the nature if their function they get hot but I would hate to burn out another one. The battery and all the remaining wiring is fine. The bike is a low miler I've had since new. Any thoughts or help would be appreciated.

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