75 400 estart with cdi charging issues

[lwb140]

Sorry , I have been unclear on the 3 wire plug on the light switch

There are 5 wires on the back of the lights switch , however they are on 2 different plugs , one plug has 2 wires and simply turns the lights off and on , the other plug has three wires and 2 of them run down to the 4 pole rectifier and one goes to ground if I remember right I don't have an updated wiring diagram for a 75 x8 with e start , all I have is what pat put links to

[JDT]

I think this makes since now.

Looking back many years ago I actualy ran across this same issue when the light switch failed.
Same thing happened, the regulator burned up. As in melted.

Bottom line is that the double pole switch has to work on both sides together.
I think what happens is you end up sending DC to the regulator which is a no-no.
This type of regulator is for AC only.

DC regulators have 3 or 4 wires.
AC regulators only have 1 or 2 wires.

So too make a long story short....
I know, too late.
The second connector on the headlight switch has to be plug in.

[HoosierDeereMan]

Todd,

I think you better change your user name from JDT to CGT (Circuit Guru Todd). Great job on this one,

Troy