Had battery switched on for port motor running bilge pumps the other day, while standing in the bilge I happened to touch the alternator shaft as it extends beyond the pulley, it was hot. When running, alternator shows battery charging (ampmeter) and good voltage. Anyone see this before? BTW keys were not in the switches.

The voltage regulator usually "turns on" the alternator once the motor starts and the regulator senses the spinning of the alternator. You voltage regulator could be "on" all of the time while still performing it's other duties just fine.

My alternator will sometime not "turn on" until I rev the engine the first time. I can see the voltage at ~12v until I rev the engine the first time and then it jumps up to ~13.5 and remains there. I have a "lazy" regulator and yours is working too hard!

Just turned on batt one (starb.) and left for about 20 minutes, starb. alt shaft did not heat, but port did feel like it was getting warmer. I guess it is time for a real rebuilt alt, any suggestions need marine type three wire to stay stock.