My dad has a 93 Aspencade. He recently replaced the brushes, rear bearing and regulator in his stock alternator which wasn't charging. Everything went together smoothly. Once reinstalled, the alternator heats up so hot you can't touch the unit while the bike is running. We tried several different scenarios to eliminate possible causes, (battery, connections, etc). This is what we know; the unit doesn't heat up while running w/o the main wire being connected. It only heats up when conneceted. Even taking all the fuses out not essential to start the bike, the unit still heats up. It puts out 11.5 to 12 volts at idle and at 2000-2500 rpm it shows 13.5, so it's charging fine. Battery is a fairly new Diehard. This bike has been his pride and joy. He's in his 70's and is a great mechanic but doesn't have the resources to relace this unit. Personally, I not so sure replacing the unit will fix his original problem. But if any of you can offer any direction, I would greatly appreciated it.