Thank you TM regarding Silicone. I have the thin spray stuff for locks and the thick vacuum grease for plastics and electrics. I had a voltmeter that lasted 2 startups. I bet the inductive spike from the rotor got to it. When testing my rotor by measuring its current drain I was surprised how big the induced spark was when I removed my temporary power wire. So I installed a diode across the brushes in a similar manner to TM. Here is his thread on the topic: http://www.xs650.com/threads/alternator-rotor-inductive-kickback.42605/#post-425493 Thank you again TM.