All the bits arrived quick as lightning and packed better than anything you get off ebay care of Bo, so big thanks again to him. I got instruction by email:
Here are a couple of pics showing how to hook up the rec and reg. When I say switched 12V source I mean any wire that has 12V on it with ignition on and 0V with ignition off - you can hook it up to the wire that feeds your coils, the wire that feeds your brake light switch, basically any switched 12V source will do. I don't know how much of the stock wiring is left on our bike, but stock colour for switched power is brown. The green wire coming off the regulator is the power wire for the field coil - there should be a green wire running along the stator wires, that's the one you should connect to.The rest should be fairly self-explanatory, but don't hesitate to ask if you have any questions.
As for leaving the parts open to the elements, I don't see any problems there - I had the rectifier mounted under the stock battery box, which leaves it pretty much unprotected. The regulator was mounted in the stock position under the left side cover which is sort of semi-protected, never had any problems. It's a bit hard to see in the picture you sent me, but is the front of your electronics box solid? If so that may be a problem (wrong rec/reg aside) - the coils will get a bit hot when running and will need some air too cool them. You might want to cut some slots or holes in the front of the box, maybe a large hole with some grating installed to get airflow around the coils.
We put the rectifier on first and jammed it into a tiny space behind the battery, alongside the light switch with a bit of rubber inner tube shielding it and keeping it separate. Alongside that was a strange looking thing with the main + wire to the battery.
I am guessing from the manual that this is a starter relay. Alongside that is the back of the ignition key so its quite a squeeze. Wiring up the three yellows tidied up my wiring a lot and it was fun crimping up new connectors on old bits of wire.
Once the rectifier was wired up and in place my friend drilled a new hole to fix up the regulator under the battery box and we made up some longer bolts which came with the ignition coil mounts which I didn't use. We attached the brown straight to the back of ignition key, the black to the frame, but then we realised we couldn't find the green. The equivalent on the reg/rec we removed went nowhere and was folded on itself in the box. Tracing the stator wires we found an extra wire which went straight to the ignition key so we took that off and wired it to green on the regulator.
Fired it all up and it started great. Riding round the block (I hope I don't get an ASBO) it wasn't running right, but it seems to be one of the cylinders so I'll have a look at the top of the coils etc again in the morning. Anyway I was pleased it started.
UPDATE: Nope. I pulled an HT lead off the coil and widdened the hole so it jammed on a bit better, put it all back and now I am getting no spark nowhere. I am sure I have done something obviously stupid. I am running out of warm days to ride as well..
Small bike syndrome
13 hours ago