For the regulator, I removed all the wires except the red wire from the connector shell. There was no sign of damage to the red wire in the harness so I decided to use the stock T instead of going directly to the battery. I installed new bullet connectors with my crimping tool from Vintage Connections. My first few practice crimps were terrible, but these three are (almost) perfect.
I added some plastic tubing to protect the wires. When the regulator is reinstalled I plan to relocate the stator wiring so I can make the connections under the battery box. This will allow me to get to the connectors without removing the battery.
And here is what I removed from the circuit. The three green wires were 13.5 inch extensions so the stator wires would reach the harness. One green wire is a bit shorter than the others because I used it for practice crimps. The yellow and white/blue wires were removed from the connector shell that connected the stator to the regulator. Both wires had signs of overheating (brittle discolored insulation) and the missing pin on the white/blue wire was melted into the connector shell. Only a few strands of wire were attached to the pin.
This wiring mod also removes the infamous headlight switch loop in one phase of the stator to regulator wiring.
It's not much, but the charging system should be a lot happier after this change.
Jim
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