I installed the SH775 but need to know how to replace the circuit at the light.

[Rich82GS750TZ]

If you have a stator with 4 wires, it is the wrong stator.

[Nessism]

Reading back through this, it's unclear if you have the bike sorted or not.

Just to be clear...disconnect both the regulator and rectifier and remove them. When removing the rectifier, take note of the RED bullet connector. You will reuse this connection. All others can be taped up and stowed away.

Find a place for the SH775, and mount it to the frame.

Find the wires coming from the stator. There will be a wire bundle coming from the stator cover. Disconnect these wires from the main harness. Route the bundle up by the SH775, to check length and harness routing. It doesn't matter what colors these wires are, these three must be fed directly into the SH775.

Take the negative output from the SH775, and route it up to the battery negative post.

Take the positive output from the SH775, and connect it to the red bullet connector feeding your main harness. This red wire was previously connected to your rectifier.

Check charging system output by reving up the engine to 5000 rpm. You should see between 14-14.5 VDC. The battery must be charged or the output will be low.

[Grimly]

I just figured it out. The white and green wire runs from the stator to the light switch and then back to the rectifier as the white and red. When the light is switched "on" the bike will charge but will not when the lights are turned off. I am not sure why it was wired this way. I have a 1979 GS1000L.

It was wired that way to alleviate the load on the stator when the bike was running with lights off. Due to a peculiarity of the cheapskate regulator/ rectifier design, the stator is always running at full belt and when the headlight is on, that's ok. When the headlight is not on, Suzuki used those two long wires to also switch off a phase of the stator's output and helped keep it cooler than otherwise.
Due to the cheapskate nature of the reg/rec, the stator will eventually burn out, but that's ok, because it was usually in the hands of the third owner or so, so Suzuki were off the hook and could charge a few hundred bucks for a replacement.
With the advent of teh SH-775, all this changed, and proper governance of the electrical output could take place with no need for the extra wiring and switch malarkey.

[dubwicht]

Thanks Dave - great explanation.

[dubwicht]

My stator actually had 5 wires - Green/yellow, two yellow and two blue and white. However, the two yellows and the two blue and whites are connected in the harness. I cut one of each and now have 3 wires. The spits are shown on the schematic.