I’m having issues with a Buddies bike that has me baffled. The main problem is not charging and it is a long story but will make this as short as I can with all the facts.
I trouble shot this issue to rotor due to following, stator test good no grounds ohms read .2 but voltage @300 rpm is only 38 volts. Advised buddy to but rotor, he bought a complete Accel 32 amp kit. Stator Rotor and VR, installed it, guess what same issue. But now stator is putting out 44 Volts.
We eliminated bike by testing charging system with carbon pile load tester. Disconnected VR from bik, attached load tester, started bike, cranked load to 20 amps, VR only puts out 9 VDC.
Attached another VR got exact same readings. Pulled off primary AGAIN, can see no issues what so ever.
While looking at the difference between the rotors I noticed one seemed to place the stator .180 in father away from stator. In essence moving the stator to a different magnetic area within the rotor. Was so confident this would fix it made a $50 bet on it, I lost. But it did change the voltage to 41 VAC.
This is driving us both mad, this is basically a lawnmower charging system, spin magnets by an iron core wrapped with copper wire and boom you make electricity.
So here’s what we’re down to magnets in 2 different rotors are not strong enough to produce 60 VAC, I just can’t believe this is the problem. Attached is a pic of system he installed.

Has anyone EVER seen anything like this?