1. Disconnect the battery.  Remove the front engine cover and filter housing cover. Disconnect and pull all the wires through into the filter housing.  Take off  the magneto and dynamo.

3. Offer stator plate and stator onto the bottom taper. Tighten  the screws  a little at a time until the unit is full home. Ensure the two yellow wires (on right) and the pickup wires (on left) are not trapped.  

4. Offer the HT coil bracket and coils onto the two 6 mm studs either side of the original magneto position. Thread all wires to the front of the bracket and feed the HT leads through the top tunnel and out of the holes to the sparkplugs.  (N.B.  Liquid soap on the leads helps them slide through the rubber grommets in the case.)

5. Place the earth ring terminal (brown wire) onto the left hand stud and fit the washer and M6 nut.

6. Place the CDI unit into the  upper casing.  Connect the single black/red wire from the original magneto to the black wire on the CDI.  (Ignition cut-out.) The red, yellow and brown from the stator plate go to the matching colours on the CDI unit.

7. Fit the rectifier/regulator onto the L/H top engine steady and thread the two yellow wires through the top tunnel connecting them to the two yellow wires on the stator, (either way round around.)

8. Thread the blue and brown wires from the CDI box through the top casing hole between the HT coils and push the spade connectors onto the coils.  (The brown wires connect to the green coil spades.)

9. Connect the original brown dynamo wire to earth. Join the two thick dynamo wires together and connect them to the red on the new rectifier/regulator.  The thin blue dynamo wire was for the charging light and is not used with this system. Isolate this wire with tape. (N.B. Original wiring harness colours may vary so confirm wire colours if your bike has been re-wired.)  

10. Take the rubber bung from the crankcase timing hole and rotate the motor until the top of the “F” mark is just visible at the bottom of the hole. (See inset right.) Offer the flywheel onto the crank taper lining the two marks up on the wheel and back-plate, then put the washer and nut on and  tighten. Give the bolt a final tap to drive the F/wheel onto the taper.

11. Screw the plug caps onto the HT leads and start the engine. Fit 12 volt battery & bulbs. Strobe the ignition if possible. You may need to advance or retard the motor a little.  If so use the supplied extractor to remove the flywheel and adjust timing.  

N.B.  This unit can work without a battery fitted  but for optimum stability of ignition and lighting you should fit a suitable 12 volt battery to complete the system.