Using the same process, make the DC power adapter harness. The FH012AA only has two output pins on the DC power side, one for positive and one for negative. The kit I bought came with these already marked with a red and green sticker. You will notice the center pin in the black connector is missing. This pin is not used, which is why you have one extra contract in your kit. In the diagram below I have tried to clarify this with pin descriptions.
Since the factory RC-51 regulator has two wires for positive and two wires for ground we are going to have to splice them together when crimping down the contacts. You will also notice there is a smaller black wire going into the factory reg/rec. This wire is a switched 12V sense used by the factory regulator to adjust output voltage. The FH012AA regulator does this internally so this wire can simply be capped and left unconnected. The DC adapter harness is going to looks like this:
Install the yellow environmental seal into the middle unused pin. Twist both green, and both red/white wires together and install the environmental seals. Leave the black wire unconnected as shown below:
At this time I re-installed the flexible clear plastic boot that came with the factory regulator over the beige connector. I also slid a piece of heat shrink over the wires that will be used to secure the disconnected black wire.
Crimp the contacts as in the first harness. This time I chose to solder the contacts to the wires AFTER crimping. The after part is crucial. I have seen people solder wires together and then crimp the wires. This is a big no no as the solder eventually gets "crushed" in the crimp and then you have a poor connection which arcs and sparks and catches on fire and makes for a pretty bad day. I chose to solder these contacts because we are putting two wires in a contact really meant for one wire. This is fine as long as we make sure it is connected properly. This is why we solder just to make sure the wires are making an excellent connection and wont come out of the crimp.
So now install the contacts into the black FH012AA connector. Make sure to observe polarity! If you accidentally installed the contacts incorrectly, it's easy enough to take the contacts back out. There is a small clip you can see looking into the connector. Push this down with a small flat head and remove the contact. Next, Slide the environmental seals into the connector and secure the black wire with the heat shrink. I didn't take any pictures of my finished harness (sorry!) however you can see it in the last picture with the regulator installed in my bike.
Hokay so.... you need a bracket to mount your new regulator. Now is the time to get creative. This is how I did it: I had a thin sheet of aluminum laying around that I used to make a bracket out of. You can usually get pieces of aluminum like this anywhere. Home depot, metal fabricators might even give you a piece of scrap for free that will work great. I had a piece thin enough I could cut it with tin snips. This seems too thin, however once bolted to the bike, it is extremely structurally sound. I put some bends in the bracket so the regulator was slightly offset from the sub frame. This makes bolting everything up much easier because you can get to the nuts. Here is the bracket:
I had to dig through a stock pile of fasteners I have to bolt everything up. If you don't have a stock pile; Ace Hardware is a good source, Home Depot, many places will have the 4 bolts and 2 nuts you need. Here is the bracket installed:
All that's left now is to bolt everything up and connect the harnesses:
Enjoy your new charging system!