Wrong.All of them or some wires in particular?
Basically, the charging system puts out full power all the time, the reg shorts the excess to ground keeping the voltage working normally. Thus, with no load the reg is working the hardest and with lots of load its working the least. Of course, the regulated current wires comming out of it carry the most amount of current under a high load and the least at minimal loading.....
My guess would be that somewhere a wire got rubbed though and shorted to ground.
Umm you're wrong cyclecamper. :bitchslapWrong.
Modern regulators use TRIACs or SCRs to regulate the duty cycle of the waveform to PASS the amount of current (number of coulombs of electrons) needed to achieve the target voltage actross the load resistance. There is no "shunting of excess to ground" and when no charging is needed and no current needs to pass to the battery then the 3-phase AC alternator sees VERY high impedance, not low: it is not shorted to ground, it's an open circuit. These are similar to other PWM regulators, which are among the most efficient regulators (though alternators that regulate a field coil can be even more efficient). If they shunted to ground that would be phoenomenally stupid, since the alternator would be running balls-out all the time and always laoding the engine the max it could, robbing valuable horsepower and turnign it into heat, and the left side alternator cover would always be burning hot, much hotter than it is, and the regulator itself would be burning hot all the time.
Umm you're wrong cyclecamper. :bitchslap
Our bikes use a permanent magnet alternator. The stator coils are shorted to to shunt excess current. They work at 100%. The higher the load on the electrical system the kinder it is to the regulator as it has to shunt less.
This is why it is important when jump starting to use a vehicle that is not running. If it is running and holding the voltage above the regulator setpoint the regulator has to shunt 100%, it wont like that for long.
edit: Have a look at the circuit diagram for the regulator on pages 7-5, read the description too. But don't just trust the Suzuki manual, google it and you'll find it's how permanent magent alternators regulate.