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Thank you for this Thread, I have solved my charging problem. I will create a image gallery soon, and post all my extra images. Someone posted that they used a BWD Select R296 Voltage Regulator, Once I confirmed that this was the one for the 81 XS400SH I jumped at it. While I was on the O'Reillys website, http://www.oreillyauto.com/ I noticed that there is a set of Pigtails to go with it. Its not that I am lazy, I just don't like trying to attach things to inside prongs. What if ... It gets too hot, ... KISS One less thing for me to try to create and troubleshoot.
I Crimped and soldiered (is that a word) Green to green, the Blue pigtail to the Bikes Brown, then one of the screws that I used to secure the regulator, I attached a ground wire, and included that into the wiring harness. that was Black to Black. I tried to keep it simple.
I had added a bigger fuse block to my bike, and the fuse block holder was able to accommodate the addition of the new Voltage reg, and conviently it was next to the bikes wire harness connector. The fuse block holder is made from aluminum. so I dont know how conductive the aluminum is, so I put a ring terminal on the bolt that was holding it, to ensure good ground or earth path. so when I post the gallery pictures, The Fuse block base (bottom) I was able to drill 2 holes for the Voltage regulator (VR), which extends the VR along the plastic of the wheel well, smashing it quite snugly next to the battery box.
