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I rewound the stator, added a voltage regulator/rectifier and am floating the ground.
At slow idle I have about 6V DC, just above idle it pops right up to 12-13V. But at high revs the volts jump and stay over 20.
The reg/ret is just a cheap one http://www.amazon.com/Promax-Regulator- ... op?ie=UTF8 is that my problem?

All measurements are straight off the regulator.

OK. pulled a good regulator off the wifes ttr, and it only put out 9V.....

Where did you find wire for the rewind?

What are your ohm readings?

Approximately how many feet did you wind?

Have you tested it with a load on it ?

Sorry I didn't get back sooner, been backed up in the garage.

18ga magnet wire, don't know how many feet. It ended up being the same thickness as the stock one.
I'm not smart enough to know how to load test it.

Still working this problem.
Got a new regulator (trail tech) and rewound the stator just in case.
Stator puts out around 7V AC at idle and will go over 30 when reved.
The regulator puts out at most 7 or 8V DC at idle and drops voltage when reved.
I am stumped and about to give up on the idea of riding this bike on the street.

Got it figured out, have to have the battery for the regulator to work. Hadn't planned on using a battery.