How to fit Podtronics regulator rectifier

Get in touch with Alan Osborn at  AO Services.

There are a few schematics on my site that cover aftermarket 'upgrades'

https://granttiller.com/norton-commando-wiring-diagram-podtronics

...PODtronics (among other manufacturers) do not support the Lucas 3AW silver can warning light assimilator, so you'd be well advised to find an alternative.

Rather than fitting a combined reg/rec, an alternative would be to fit a replacement rectifier.

A modern rectifier is encapsulated in resin – they are robust and are much better at resisting vibration - they are less than five dollars to buy, work perfectly and are a wire for wire replacement for the original Lucas LU49072 (2DS506)

The capacitor is a consumable item - they 'only' last around thirty years in use. If you have the original one, you can remove it from the bike. 

The PODtronics has a very small smoothing capacitor built in. 

You can easily buy a replacement if you want to retain the capacitor.

Here is a diagram that shows swapping the zener and rectifier for a PODtronics (with and without the capacitor)

As you have already bought the Podtronics unit you may as well utilise it. I have fitted these previously and they work well. If yours has four wires there should be two yellow and one black and one red wire. Assuming your alternator has two wires that previously connected to the now defunct rectifier then these attach to the two yellow Podronics wires (it does not matter which way around - If by chance your Podtronics box has three yellow wires then connect two together (it doesn't matter which) and connect these 'paired' wires to one of the alternator wires).
Assuming your bike is the standard positive earth set-up then the red Podtronics wire connects to the frame and/or the wire that connected to the + terminal on the old rectifier. Likewise the black Podtronics wire connects to the wire that connected to the - terminal on the old rectifier. That should be it! Ensure that the Podtronics unit is bolted to somewhere with good airflow as it needs some sort of cooling/heat-sink. How you connect the wires is up to you - I tended to use good-quality 'bullets' and ensure they are well insulated.

HtH.

BUT with above diagrams...there is numbers inserted 1-4 why? there is no numbers on any diagram or unit? The Rectifier as mentioned above are good, but are for use with the original Zener diode IF it is in good order. The Warning light assimilator (original equipment) needs to be removed IF you fit the Podtronics/Regulator Rectifier. Finally If you buy an aftermarket unit then it MUST come with adequate instructions, or it makes it not fit for purpose.

I numbered the original rectifier terminals and the wires on the PODtronics in order to make it crystal clear how it should be wired in.

Apologies if my explanation is not up to your standards.