Hitchcocks Forum

Hi All, I wonder if anyone can help with a charging issue I've got? The set-up is a 1992 Bullet 500 with a new higher output alternator stator from our hosts, Boyer Brandson powerbox (over a decade old), brand new battery and halogen 55/60w headlamp. The bike starts and runs fine and does show a small charge on the ammeter with no lights on, but a large discharge when I turn the headlight on, regardless of revs. I'm getting 5 amps and 25 volts from the alternator at medium revs (I am on the original rotor, but it will support it's own weight from a steel bar, so I'm guessing it's magnetism hasn't leached away), but only 1.5 amps (through the red lead to the battery) and 13.5 volts from the powerbox at medium-high revs regardless of load. I have fitted a 10A fuse in the red powerbox lead as recommended, which hasn't blown. I would have thought this set-up would easily have coped with the more powerful headlamp bulb, so my question is shouldn't I be getting more current from the powerbox to the battery? Is it fried or am I barking up the wrong tree and should be looking for another problem? Many thanks in advance!