On high beam it had a flicker and brightness varied for no reason. A steady 5k rpm and it varied in brightness and flickered.
Just to confirm, this is with the LED bulb? If so, if you haven't already, disconnect your Rec/Reg and try again. With nothing feeding the battery, there should be no ripple on the battery. No AC ripple should mean steady DC and no flickering.
Someone help me here. Is the hi-beam wattage any higher than low beam or is it just the angle of the light?
Run a test lead from the battery to the bulb...use the diode as the other test lead. If the bulb illuminates, reverse the diode leads...it should not illuminate, unless the diode has failed.
Great suggestion.
Are you using the small AC to DC power supply for any of this testing? Reference post 30.
I have a charge rate of 12.5 v at the Battery. I want battery fed led and no flicker.
it may not be charging. Remove the TL and see if the battery voltage increases from idle. Feel confident the Rec/Reg can supply 2ish amps at 12v. Maybe remove the TL bulb to reduce your load even further and try again.
Just an opinion here based on what I see and my VERY limited knowledge of your stator and Rec/reg. You have way more capacity in that stator than you have in your rectifier/regulator. However, with all LED lighting, and my guess is correct on Rec/Reg (~2 amps), you have plenty of juice to keep the battery charged. I also don't see a need to use the the power supply you ordered.
If you don't get this solved in a day or 2, maybe I can meet you downtown Charlotte at one of the local Breweries one warm afternoon. I work cheap if free beer is involved.